Research Papers

Newest Developments on the Manufacture of Helical Profiles by Hot Extrusion

[+] Author and Article Information
Nooman Ben Khalifa, A. Erman Tekkaya

 Institute of Forming Technology and Lightweight Construction, TU Dortmund, DE 44227 Dortmund, Germany

J. Manuf. Sci. Eng 133(6), 061010 (Dec 01, 2011) (8 pages) doi:10.1115/1.4005116 History: Received April 01, 2011; Revised September 09, 2011; Published December 01, 2011; Online December 01, 2011

A new innovative direct extrusion process, helical profile extrusion (HPE) is presented, which increases the flexibility of aluminum profile manufacturing processes. The application fields of such profiles can be seen in screw rotors for compressors and pumps. The investigations concentrate on experimental and numerical analyses by 3D-FEM simulations to analyze the influence of friction and the material flow on the twisting angle and contour accuracy. By means of finite-element method (FEM), the profile shape could be improved by modifying the die design. The numerical results were validated by experiments. For these investigations, a common aluminum alloy AA6060 was used. Mainly, the friction in the die influences the twist angle and the shape of the helical profile. Two die coatings were analyzed, but the friction was not substantially decreased in any of these cases. Although there is no efficient practical solution for reducing the friction in extrusion dies using tested die coatings, the required profile contour could be achieved by new die designing and by modifying the material flow. However, increasing the twist angle is limited due to geometrical aspects of this technology, namely, by the ratio of the volume to the contact area with the die for the displaced metal.

Copyright © 2011 by American Society of Mechanical Engineers
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Figure 1

Process principle of HPE [3]

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Figure 2

Spanned die for HPE and extruded profile [3]

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Figure 3

Comparison of the profile contour for different twist angles

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Figure 4

Simulation model with DEFORM 3D

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Figure 5

Velocity distribution in the Cross section of the extruded profiles in the die (z = 4 mm, z = 12 mm, z = 18mm, and z = 25 mm) and the comparison with the inner contour of the die

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Figure 6

Strain distribution in the Cross section of the extruded profiles in the die (z = 4 mm, z = 12 mm, z = 18 mm, and z = 25 mm)

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Figure 7

Cross section of the extruded profiles at the die entrance (with z = 4 mm) for three different friction values

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Figure 8

Equipment of the small scale extrusion

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Figure 9

Etched section of deformed rod-added billets [17]

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Figure 10

Load-stroke curves, different coatings

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Figure 11

Optimization of die design and verification of the material flow by means of the FEM Simulation

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Figure 12

Redesigned die, CAD model, and real die

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Figure 13

Comparison of the profile contours before and after optimization

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Figure 14

Increasing the twist angle by using a porthole die; (a) The developed die and (b) hollow profile with increased twist angle

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Figure 15

Influence of the profile geometry on the twist angle by using hollow profile or by scaling down the geometry



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