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Technical Brief

Mathematical Analyses and Numerical Simulations for Forward Extrusion of Circular, Square, and Rhomboidal Sections From Round Billets Through Streamlined Dies

[+] Author and Article Information
Ahmed Waleed Hussein

Department of Mechanical Engineering,
University of Babylon,
Babylon 00964, Iraq
e-mail: ahmed_wleed_1988@yahoo.com

Abdulkareem Jalil Kadhim

Department of Mechanical Engineering,
University of Babylon,
Babylon 00964, Iraq
e-mail: drkareem959@yahoo.com

Manuscript received February 22, 2013; final manuscript received October 27, 2016; published online January 11, 2017. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 139(6), 064501 (Jan 11, 2017) (7 pages) Paper No: MANU-13-1073; doi: 10.1115/1.4035123 History: Received February 22, 2013; Revised October 27, 2016

In the present investigation, an analysis using three-dimensional upper-bound method based on continuous velocity filed has been carried out for the extrusion of circular, square, and rhomboidal sections from round billets. The die surface representation in the present work could easily be applied to the extrusion of many different shapes just by defining the functions that describe the entry and exit sections and putting them into the general formulation. The die profile was tested for the third- and fifth-order polynomial functions. The extrusion process is also simulated using the finite element code, ansys (V 14.0), in order to assist the mathematical solution and to show the stress and strain distributions for the products when the strain hardening effect is taking into the account. Effects of friction, shape complexity, reduction of area, and die length on the extrusion pressure were also investigated. The results obtained in this work were compared with the theoretical results of other workers and found to be in highly compatible.

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Figures

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Fig. 3

The die surface for the extrusion of rhomboidal or square sections from round billet

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Fig. 2

Die surface for the extrusion of circular section from round billet

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Fig. 4

Meshed models: (a) rhomboidal section (DR = 0.8) and (b) circular section

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Fig. 1

General die shape [6]

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Fig. 5

The relative die length against total relative extrusion pressure for the circular section

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Fig. 6

The relative die length against total relative extrusion pressure for the rhomboidal section

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Fig. 7

The results comparison for the circular section

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Fig. 8

The results comparison for the rhomboidal section

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Fig. 9

Area reduction and friction factor against the relative extrusion pressure for the circular section

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Fig. 10

Area reduction and friction factor against the relative extrusion pressure for the rhomboidal section

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Fig. 11

Circular section: (a) Von Mises stress contour (MPa) and (b) Von Mises plastic strain contour

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Fig. 13

Square section (DR = 1): (a) Von Mises stress contour (MPa) and (b) Von Mises plastic strain contour

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Fig. 14

Punch pressure against punch displacement

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Fig. 12

Rhomboidal section (DR = 0.8): (a) Von Mises stress contour (MPa) and (b) Von Mises plastic strain contour

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