The forming characteristics of radialforward extrusions

1
The forming characteristics of radial-forward
extrusions

• Y.S. Lee, S.K. Hwang, Y.S. Chang, B.B. Hwang

Journal of Materials Processing technology, 15
June 2001
Presented by, Douglas Merrell September 15,
2004
2
Introduction

• The four basis types of extrusion are direct
  (forward), indirect (backward), hydrostatic, and
  impact
• New types of extrusion are being developed
  including radial extrusion

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Introduction

• In conventional extrusions material flows
  parallel to the punch or die
• In radial extrusions the materials flow
  perpendicular to the punch or die

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Examples of Radial Extrusion Parts
Radial Extrusion is used to create universal
joints, tube fittings and differential gears
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Introduction

• The researchers developed a model using the
  rigid-finite element method
• Using this model they were able to simulate
  changes in design parameters
• Then they were able to determine the effect of
  certain parameters on the power requirements

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References

• 1 S. Kalpakjian, Manufacturing Processes for
  Engineering Materials, 2nd Edition,
  Addison-Wesley, USA, 1991, p. 363.
• 2 J. A. Pale, T. Altan, Development of
  equipment and capabilities for investigation of
  the multi-action forming of complex parts, Eng.
  Res. Center Net Shap Manuf. (1989) 8.
• 3 M. J. Saran, Journal of Materials Processing
  Technology. 27 (1991) 279.
• 4 Air Force Materials Laboratory, Forging
  Equipment, Materials and Practices, Metals and
  Ceramics Information Center, 1973. p. 164.
• 5 E. Paul De Garmo, Materials and Processes in
  Manufacturing, Macmillan, New York, 1967, p. 27.
• 6 E. Paul De Garmo, Material Properties and
  Manufacturing Processes, Malloy, Ann Arbor, MI,
  1966, p. 31.
• 7 J. Datsko, Material Properties and
  Manufacturing Processes, Malloy, Ann Arbor, MI,
  1966, p. 31.
• 8 Metals Handbooks, The Materials Information
  Society, Vol. 2, 10th Edition, p. 104
• 9 S. Kobayahi, S.I. Oh, T. Altan, Metal Forming
  and the Finite Element Method, Oxford University
  Press, London, 1989, p. 30.
• 10 T. Huziyoshi, Die and Moulding, Daily Tech.
  Press, Tokyo, 1989, p. 446.
• 11 S. H. Lee, Forming characteristics of radial
  extrusion, Master Dissertation, Inhan Graduate
  School, Inchon, 1999, p. 20.

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Model Part
b bottom thickness d0 billet diameter dA
mandrel diameter h0 billet height h1 workpiece
height hst punch stroke rA die radius ru
deflection radius rG mandrel radius Ss gap
height SR annular gap width Sw wall thickness
Billet diameter Billet height Punch
stroke Mandrel diameter Die radius Deflection
radius Mandrel radius Gap height
16mm 70mm 40mm 28mm 2mm 2mm 2mm 4mm
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Material Properties

• Using AA 6063 Aluminum alloy
• Cold working (strain rate not a factor)

Calculated from sy, E, e, and Su
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Simulation
Maximum pressure is 3257 MPa
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Simulation
Verification that the model matches experimental
tests Accurate to within 5
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Design Parameters

• This paper choose to study
• Mandrel diameter (dG)
• Die radius (rA)
• Friction factor (m)
• From previous studies 11 the gap height was
  known to have a large effect on the load. It was
  held constant.

b bottom thickness d0 billet diameter dA
mandrel diameter h0 billet height h1 workpiece
height hst punch stroke rA die radius ru
deflection radius rG mandrel radius Ss gap
height SR annular gap width Sw wall thickness
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Friction Factor
Friction has a large effect after 12.5 mm
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Mandrel Diameter
Shows the effect of the mandrel diameter on the
load requirements. The greater the diameter the
greater the load necessary.
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Die radius
As the die radius gets larger the force
requirements get smaller, but the die radius has
the least effect of all the design parameters
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Conclusions

• The friction factor has a large influence on the
  mandrel load but not on the punch load
• The load increases with the mandrel diameter and
  the friction factor
• The load decreases slightly with an increase in
  the die radius

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Conclusions

• The mandrel diameter has the greatest effect and
  the die radius has the least
• Each of the design parameters had little effect
  on the punch load
• The punch and mandrel loads are similar during
  the radial extrusion but diverge at the start of
  forward extrusion

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Questions?