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FEM Numerical and Experimental Study on Dimensional Accuracy of Tubes Extruded from 6082 and 7021 Aluminium Alloys. | LitMetric

AI Article Synopsis

  • - The extrusion of hollow profiles from AlZnMg alloys using porthole dies is challenging due to high extrusion forces and friction, leading to dimensional inaccuracies in the final products.
  • - A new die design, referred to as die 3, was developed with modified geometry and features, and was tested against existing dies for producing Ø50 × 2 mm tubes from the 7021 alloy.
  • - Research showed that die 3 achieved high dimensional accuracy for both 6082 and 7021 alloys, while older dies resulted in significant dimensional deviations, especially in the physical characteristics of the extruded tubes.

Article Abstract

The extrusion of hollow profiles from hard-deformable AlZnMg alloys by using porthole dies encounters great technological difficulties in practice. High extrusion force accompanies the technological process, which is caused by high deformation resistance and high friction resistance in extrusion conditions. As a result of high thermo-mechanical loads affecting the die, a significant loss of dimensional accuracy of extruded profiles can be observed. The different projects of porthole dies for the extrusion of Ø50 × 2 mm tubes from the 7021 alloy were numerically calculated and then tested in industrial conditions by using a press of 25 MN capacity equipped with a container with a diameter of 7 inches (for 7021 alloy and 6082 alloy for comparison). New extrusion die 3 with modified bridge and mandrel geometry and a special radial-convex entry to the die opening was proposed. FEM was applied to analyse the metal flow during extrusion, geometrical stability of extruded tubes and the die deflection. The photogrammetric measuring method was used to evaluate dimensional accuracy of tubes extruded in different conditions and geometrical deviations in porthole dies elements, especially the bridges and the mandrels. Research revealed a high dimensional accuracy of tubes extruded from the 6082 alloy and from the 7021 alloy by using original extrusion die 3, while much higher dimensional deviations were noted for tubes extruded from the 7021 alloy by using extrusion dies 1 and 2, particularly in relation to the circularity, centricity and wall thickness.

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Source
http://www.ncbi.nlm.nih.gov/pmc/articles/PMC9865809PMC
http://dx.doi.org/10.3390/ma16020556DOI Listing

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