Title: EFFECT ON ROD AND TUBE EXTRUSION CONSIDERING VARIOUS DIE ANGLES USING PLASTICINES & NUMERICAL VALIDATION OF EXTRUSION EXPERIMENT RESULTS USING FINITE ELEMENT SIMULATION
Abstract:Extrusion is a relatively new process and its commercial exploitation started early in the nineteenth century with the extrusion of lead pipes. Extrusion of steels became possible only after 1930 when...Extrusion is a relatively new process and its commercial exploitation started early in the nineteenth century with the extrusion of lead pipes. Extrusion of steels became possible only after 1930 when extrusion chambers could be designed to withstand high temperature and pressure. Extrusion large number of variations in the mode of application.In the past, the extrusion dies was designed based on theoretical relations given in handbooks of metal forming. These are based on experiments carried out at wide number of cases & die behavior under various conditions. In many cases, this trial-and-error procedure is neither optimal nor cost effective in terms of achieving the desired properties in the finished product. Also such approaches lack clarity with respect to mechanics of metal flow, enhances the design time and end with lower efficiency. Extrusion die angle & die landing plays an important role on material flow, micro structural evolution, speed of production and left out material in the die. Faulty die landing may lead to material wastage through large dead metal zone and bad microstructure. In this study an attempt has been made to study the effect of die angle on rod & tube extrusion processes using experiment. The extrusion experiments are carried out by using three dies of different die angle with variable die landing and at the three different speeds. Red and Green colors plasticine is used. Extrusion load increases with increase in ram velocity irrespective of die angle and material. Simulation study reveals a good match between experimental and numerical load stroke curves. It shows that simulation can be effectively used for the analysis of extrusion process. The designed die was further adopted for computer simulation using MSC. Super forge software (based on FE Method) to asses stress, strain and strain rate distributions and load requirements. Using these results, effects of different die angle & die landings at various ram speeds are critically examined. The expectation of this study would provide a new insight into the design of manufacturing process. Keyword-Extrusion Dies, Red & Green plasticine, Manufacturing process, Die angles, Tube, Rod, AluminiumRead More
Publication Year: 2012
Publication Date: 2012-01-01
Language: en
Type: article
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