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Effect of process parameters on metal flow and dead metal zone in extrusion

Effect of process parameters on metal flow and dead metal zone in extrusion,Sayyad Z. Qamar,Tasneem Pervez,Abul Fazal,M. Arif,Anwar K. Sheikh

Effect of process parameters on metal flow and dead metal zone in extrusion   (Citations: 2)
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Extrusion finds increasingly more frequent and important applications in automobile, aircraft, construction and other industries. Optimization of metal flow is crucially important in both design and manufacture as it directly affects extrusion speed (essential for higher productivity) on the one hand, and mechanical properties and surface finish of the extruded product on the other. It is reasonable to assume that material flow properties, die-workpiece and container-workpiece heat transfer and friction conditions, die profile, and die design all affect metal flow. However, the mechanism of dead zone formation and how it affects metal flow is not understood well enough to forecast with an acceptable degree of accuracy what is actually happening. Predictive numerical models are limited because of this lack of perception of the physics of the process. The current paper presents some results from a study about the behavior of metal flow and dead metal zone in cold extrusion. Experiments have been performed on flat-face dies fabricated from H13 tool steel and heat treated and surface hardened to approximately the same specifications as commercial extrusion dies. Three workpiece materials have been experimented with: Al-6063 as it is the most common aluminum alloy in the construction sector, and pure aluminum and lead for their better extrudability. Extrusions have been carried out at four different speeds. Commercial finite element packages ANSYS and ANSYS-LSDYNA have been used for numerical investigation of the effect of variations in important extrusion parameters.
Published in 2007.
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    • ...In a previous work by the author's group [16], the effects of various process parameters (such as extrusion ratio, ram speed, extrusion pressure, and billet material) on metal flow and DMZ in metal extrusion have been looked into...

    S. Z. Qamar. Shape Complexity, Metal Flow, and Dead Metal Zone in Cold Extrusion

    • ...In a previous work by the authors [14], effect of various process parameters (such as extrusion ratio, ram speed, extrusion pressure, and billet material) on metal flow and DMZ in metal extrusion have been looked into...
    • ...[13] L. Donati, L. Tomesani, The effect of die design on the production and seam weld quality of extruded aluminum profiles, Journal of Materials Processing Technologies 164- 165 (2005) 1025-1031. [14] S.Z. Qamar, A.F.M...

    S. Z. Qamar. FEM study of extrusion complexity and dead metal zone

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