Extrusion force analysis of aluminum pipe fabricated by CASTEX using expansion combination die

To determine the extrusion force of pipe fabricated by continuous casting and extrusion (CASTEX) using an expansion combination die, the metallic expansion combination die was divided into diversion zone, expansion zone, flow dividing zone, welding chamber, and sizing zone, and the corresponding stress formulae in various zones were established using the slab method. The deformation zones of CASTEX groove were divided into liquid and semisolid zone, solid primary gripping zone, and solid gripping zone, and the formulae of pipe extrusion forces were established. Experiments were carried out on the self-designed CASTEX machine to obtain the aluminum pipe and measure its extrusion force using the expansion combination die. The experimental results of radial extrusion force for aluminum pipe are in good agreement with the calculated ones.

Plastic wrinkling model and characteristics of shear enforced Ti-alloy thin-walled tubes under combination die constraints and differential temperature fields

Plastic wrinkling predictions and shear enforced wrinkling characteristics of Ti-alloy thin-walled tubes under combination die constraints have become key problems urgently in need of solutions in order to improve forming quality in their shear bending processes under differential temperature fields. To address this, a wrinkling wave function was developed by considering their shear bend deformation characteristics. Based on this wave function and the thin shell theory, an energy prediction model for this type of wrinkling was established. This model enables consideration of the effects of shear deformation zone ranges, material parameters, loading modes, and friction coefficients between tube and dies on the minimum wrinkling energy. Tube wrinkling sensitive zones(WSZs) can be revealed by combining this wrinkling prediction model with a thermalmechanical coupled finite element model for simulating these bending processes. The reliability of this wrinkling prediction model was verified, and an investigation into the tube wrinkling characteristics was carried out based on the experimental conditions. This found that the WSZs are located on either a single side or both sides of the maximum shear stress zone. When the friction coefficients between the tube and the various dies coincide, the WSZs are located on both sides.The larger the value of the tube inner corner radius and/or the smaller the value of the outer cornerradius, the smaller the wrinkling probability. With an increase in the value of the moving die displacement, the wrinkling probability increases at first, and then decreases.

Optimized Design for a Combined Die with Two Stress Rings in Cold Forging Considering Thermal-Mechanical Effects

Stress analysis and optimization of combined die structure with two stress rings were performed.Using thermoelastic deformation,the contact pressure at the interfaces between layers was calculated.Then,theoretical expressions of stress distribution for the combined die were derived.The thermal-mechanical effect under working conditions was considered.To verify the theoretical expressions,simulation work was performed.Optimization of die design was carried out by defining radius ratio and shrink fit coefficient as optimization variables.The objective was to minimize the effective circumferential stress at the inner surface of the die insert,under the constraint that the maximum equivalent stress values of die insert and stress rings did not exceed their respective yield stresses.The Kriging model was used to describe the influence of shrink fit and die dimensions on the objective function and the maximum equivalent stress.Using a genetic algorithm,optimum parameters were found with a minimum circumferential stress of 442.9 MPa under a working stress of 1800 MPa.Further analysis of five selected optimal results was carried out,and the specific design parameters of these combined dies are different under the same level of circumferential stress,and the combined die is overdesigned if the thermal effect is ignored.

Effect of Accumulative Strain on Grain Refinement and Strengthening of ZM6 Magnesium Alloy During Continuous Variable Cross-Section Direct Extrusion

In order to study the influence of die combination on continuous variable cross-section direct extrusion （CVCDE） in the extrusion process, the accumulative strain formula is derived, and it can be known that the extrusion ratio of various stages directly determines the size of corresponding stage strain by formula. In this paper, as an example of the two interim dies, three die combinations of different angles and extrusion ratio are designed. Aviation magnesium alloy ZM6 is studied, and the results show that dynamic recrystallization is even more complete when continuous shear deformation occurs, so that the refinement and homogenization of microstructure are obtained. By the use of different die combinations, the accumulative strain increases under the conditions of same total extrusion ratio. Thus, the refined crystalline strengthening effect of extrusion deformation can be further analyzed. Due to the dead-zone defects, the actual accumulative strain decreases significantly and the effect of microstructure and performance improvements also decreases with it. Therefore, the optimal design of die combination is the key to the process and product of CVCDE, which provides a scientific basis for the development of severe plastic deformation.