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Research Papers

An Analysis of Polymer Coated Metal Rod Extrusion

[+] Author and Article Information
Jyhwen Wang1

Department of Engineering Technology and Industrial Distribution, and Department of Mechanical Engineering, Texas A&M University, College Station, TX 77843wang@entc.tamu.edu

Ritesh Shah, Yu-Hsuan Huang

Department of Mechanical Engineering, Texas A&M University, College Station, TX 77843

Der-Form Chang

 Automatic Spring Coiling, Chicago, IL 60646

1

Corresponding author.

J. Manuf. Sci. Eng 131(1), 011012 (Jan 20, 2009) (9 pages) doi:10.1115/1.3039516 History: Received May 22, 2006; Revised October 20, 2008; Published January 20, 2009

Deformable coated materials hold promises for numerous new technologies. In this research, extrusion of polymer coated metal rods was investigated. Analytical models based on upper bound method were developed to evaluate axisymmetric conical die extrusion of precoated materials. The rigid-plastic boundaries were optimized to obtain minimum extrusion power and to predict coating failure. From the models, the critical extrusion die angle can be derived. The analytical results agreed well with the results from the finite element simulation. The developed models can be used for extrusion die design and process analysis and can lead to lower cost and environmental friendly manufacturing technologies.

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Copyright © 2009 by American Society of Mechanical Engineers
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Figures

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Figure 1

An upper bound model for successful extrusion of polymer coated metal rods

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Figure 2

An upper bound model for extrusion of polymer coated metal rods with coating failure

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Figure 3

The hodograph for shaved coating

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Figure 4

FEA simulation results plotted on center bursting (internal failure) criteria developed by Avitzur (5)

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Figure 5

(a) Velocity and (b) stress plots implying center bursting failure

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Figure 6

Comparison of analytical model and FEA

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Figure 7

Velocity gradient of polymer coated rod extrusion

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Figure 8

Comparison of all the normalized length for various die angles

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Figure 9

(a) Rigid-plastic deformation boundaries for a die angle of 20 deg; (b) rigid-plastic deformation boundaries for a die angle of 45 deg

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Figure 10

Comparison of extrusion pressure required for extrusion for failure and successful extrusion of polymer coated metal rod

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Figure 11

Results of FEA simulation showing potential coating failure (at a die angle of 11.77 deg with a reduction ratio of 1.33)

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