Fabrication of fine-grained,high strength and toughness Mg alloy by extrusion−shearing process

A novel extrusion-shearing(ES) composite process was designed to fabricate fine-grained, high strength and tough magnesium alloy. The structural parameters of an ES die were optimized by conducting an orthogonal simulation experiment using finite element software Deform-3D, and Mg-3 Zn-0.6 Ca-0.6 Zr(ZXK310) alloy was processed using the ES die. The results show that the optimized structural parameters of ES die are extrusion angle(α) of 90°, extrusion section height(h) of 15 mm and inner fillet radius(r) of 10 mm. After ES at an extrusion temperature and a die temperature of 350 °C, ZXK310 alloy exhibited good ES forming ability, and obvious dynamic recrystallization occurred in the forming area. The grain size decreased from 1.42 μm of extrusion area to 0.85 μm of the forming area. Owing to the pinning of second phase and formation of ultrafine grains, the tensile strength, yield strength and elongation of alloy reached 362 MPa, 289 MPa and 21.7%, respectively.

Anisotropic time-dependent behaviors of shale under direct shearing and associated empirical creep models

Understanding the anisotropic creep behaviors of shale under direct shearing is a challenging issue.In this context,we conducted shear-creep and steady-creep tests on shale with five bedding orientations (i.e.0°,30°,45°,60°,and 90°),under multiple levels of direct shearing for the first time.The results show that the anisotropic creep of shale exhibits a significant stress-dependent behavior.Under a low shear stress,the creep compliance of shale increases linearly with the logarithm of time at all bedding orientations,and the increase depends on the bedding orientation and creep time.Under high shear stress conditions,the creep compliance of shale is minimal when the bedding orientation is 0°,and the steady-creep rate of shale increases significantly with increasing bedding orientations of 30°,45°,60°,and 90°.The stress-strain values corresponding to the inception of the accelerated creep stage show an increasing and then decreasing trend with the bedding orientation.A semilogarithmic model that could reflect the stress dependence of the steady-creep rate while considering the hardening and damage process is proposed.The model minimizes the deviation of the calculated steady-state creep rate from the observed value and reveals the behavior of the bedding orientation's influence on the steady-creep rate.The applicability of the five classical empirical creep models is quantitatively evaluated.It shows that the logarithmic model can well explain the experimental creep strain and creep rate,and it can accurately predict long-term shear creep deformation.Based on an improved logarithmic model,the variations in creep parameters with shear stress and bedding orientations are discussed.With abovementioned findings,a mathematical method for constructing an anisotropic shear creep model of shale is proposed,which can characterize the nonlinear dependence of the anisotropic shear creep behavior of shale on the bedding orientation.

Investigation of high rate mechanical flow followed by ignition for high-energy propellant under dynamic extrusion loading

Investigating the ignition response of nitrate ester plasticized polyether(NEPE) propellant under dynamic extrusion loading is of great significant at least for two cases. Firstly, it helps to understand the mechanism and conditions of unwanted ignition inside charged propellant under accident stimulus.Secondly, evaluates the risk of a shell crevice in a solid rocket motor(SRM) under a falling or overturning scene. In the present study, an innovative visual crevice extrusion experiment is designed using a dropweight apparatus. The dynamic responses of NEPE propellant during extrusion loading, including compaction and compression, rapid shear flow into the crevice, stress concentration, and ignition reaction, have been firstly observed using a high-performance high-speed camera. The ignition reaction is observed in the triangular region of the NEPE propellant sample above the crevice when the drop weight velocity was 1.90 m/s. Based on the user material subroutine interface UMAT provided by finite element software LS-DYNA, a viscoelastic-plastic model and dual ignition criterion related to plastic shear dissipation are developed and applied to the local ignition response analysis under crevice extrusion conditions. The stress concentration occurs in the crevice location of the propellant sample, the shear stress is relatively large, the effective plastic work is relatively large, and the ignition reaction is easy to occur. When the sample thickness decreases from 5 mm to 2.5 mm, the shear stress increases from 22.3 MPa to 28.6 MPa, the critical value of effective plastic work required for ignition is shortened from 1280 μs to 730 μs, and the triangular area is easily triggering an ignition reaction. The propellant sample with a small thickness is more likely to stress concentration, resulting in large shear stress and effective work, triggering an ignition reaction.

Anisotropic shearing mechanism of Kangding slate:Experimental investigation and numerical analysis

The shear mechanical behavior is regarded as an essential factor affecting the stability of the surrounding rocks in underground engineering.The shear strength and failure mechanisms of layered rock are significantly affected by the foliation angles.Direct shear tests were conducted on cubic slate samples with foliation angles of 0°,30°,45°,60°,and 90°.The effect of foliation angles on failure patterns,acoustic emission(AE)characteristics,and shear strength parameters was analyzed.Based on AE characteristics,the slate failure process could be divided into four stages:quiet period,step-like increasing period,dramatic increasing period,and remission period.A new empirical expression of cohesion for layered rock was proposed,which was compared with linear and sinusoidal cohesion expressions based on the results made by this paper and previous experiments.The comparative analysis demonstrated that the new expression has better prediction ability than other expressions.The proposed empirical equation was used for direct shear simulations with the combined finite-discrete element method(FDEM),and it was found to align well with the experimental results.Considering both computational efficiency and accuracy,it was recommended to use a shear rate of 0.01 m/s for FDEM to carry out direct shear simulations.To balance the relationship between the number of elements and the simulation results in the direct shear simulations,the recommended element size is 1 mm.

Simple shear extrusion versus equal channel angular pressing:A comparative study on the microstructure and mechanical properties of an Mg alloy

Two severe plastic deformation(SPD)techniques of simple shear extrusion(SSE)and equal channel angular pressing(ECAP)were employed to process an extruded Mg-6Gd-3Y-1.5Ag(wt%)alloy at 553 K for 1,2,4 and 6 passes.The microstructural evolutions were studied by electron back scattered diffraction(EBSD)analysis and transmission electron microscopy(TEM).The initial grain size of 7.5μm in the extruded alloy was reduced to about 1.3μm after 6 SPD passes.Discontinuous dynamic recrystallization was suggested to be operative in both SSE and ECAP,with also a potential contribution of continuous dynamic recrystallization at the early stages of deformation.The difference in the shear strain paths of the two SPD techniques caused different progression rate of dynamic recrystallization(DRX),so that the alloys processed by ECAP exhibited higher fractions of recrystallization and high angle grain boundaries(HAGBs).It was revealed that crystallographic texture was also significantly influenced by the difference in the strain paths of the two SPD methods,where dissimilar basal plane texture components were obtained.The compression tests,performed along extrusion direction(ED),indicated that the compressive yield stress(CYS)and ultimate compressive strength(UCS)of the alloys after both SEE and ECAP augmented continuously by increasing the number of passes.ECAP-processed alloys had lower values of CYS and UCS compared to their counterparts processed by SSE.This difference in the mechanical responses was attributed to the different configurations of basal planes with respect to the loading direction(ED)of each SPD technique.

Extrusion 3D printing of carbon nanotube-assembled carbon aerogel nanocomposites with high electrical conductivity

Carbon nanotubes(CNTs)with high aspect ratio and excellent electrical conduction offer huge functional improvements for current carbon aerogels.However,there remains a major challenge for achieving the on-demand shaping of carbon aerogels with tailored micro-nano structural textures and geometric features.Herein,a facile extrusion 3D printing strategy has been proposed for fabricating CNT-assembled carbon(CNT/C)aerogel nanocomposites through the extrusion printing of pseudoplastic carbomer-based inks,in which the stable dispersion of CNT nanofibers has been achieved relying on the high viscosity of carbomer microgels.After extrusion printing,the chemical solidification through polymerizing RF sols enables 3D-printed aerogel nanocomposites to display high shape fidelity in macroscopic geometries.Benefiting from the micro-nano scale assembly of CNT nanofiber networks and carbon nanoparticle networks in composite phases,3D-printed CNT/C aerogels exhibit enhanced mechanical strength(fracture strength,0.79 MPa)and typical porous structure characteristics,including low density(0.220 g cm^(-3)),high surface area(298.4 m^(2)g^(-1)),and concentrated pore diameter distribution(~32.8nm).More importantly,CNT nanofibers provide an efficient electron transport pathway,imparting 3D-printed CNT/C aerogel composites with a high electrical conductivity of 1.49 S cm^(-1).Our work would offer feasible guidelines for the design and fabrication of shape-dominated functional materials by additive manufacturing.

Modeling of recrystallization behaviour of AA6xxx aluminum alloy during extrusion process

An innovative approach was introduced for the development of a AA6063 recrystallization model.This method incorporated a regression-based technique for the determination of material constants and introduced novel equations for assessing the grain size evolution.Calibration and validation of this methodology involved a combination of experimentally acquired microstructural data from the extrusion of three different AA6063 profiles and results from the simulation using the Qform Extrusion UK finite element code.The outcomes proved the agreement between experimental findings and numerical prediction of the microstructural evolution.The trend of the grain size variation based on different process parameters was accurately simulated,both after dynamic and static recrystallization,with an error of less than 25% in almost the whole sampling computations.

Interface property of dissimilar Ti-6Al-4V/AA1050 composite laminate made by non-equal channel lateral co-extrusion and heat treatment

The purpose of this paper is to examine the effect of processing parameters and subsequent heat treatments on the microstructures and bonding strengths of Ti-6Al-4V/AA1050 laminations formed via a non-equal channel lateral co-extrusion process.The microstructural evolution and growth mechanism in the diffusion layer were discussed further to optimize the bonding quality by appropriately adjusting process parameters.Scanning electron microscopes(SEM),energy dispersive spectrometer(EDS),and X-ray diffraction(XRD)were used to characterize interfacial diffusion layers.The shear test was used to determine the mechanical properties of the interfacial diffusion layer.The experimental results indicate that it is possible to co-extrusion Ti-6Al-4V/AA1050 compound profiles using non-equal channel lateral co-extrusion.Different heat treatment processes affect the thickness of the diffusion layer.When the temperature and time of heat treatment increase,the thickness of the reaction layers increases dramatically.Additionally,the shear strength of the Ti-6Al-4V/AA1050 composite interface is proportional to the diffusion layer thickness.It is observed that a medium interface thickness results in superior mechanical performance when compared to neither a greater nor a lesser interface thickness.Microstructural characterization of all heat treatments reveals that the only intermetallic compound observed in the diffusion layers is TiAl_(3).Due to the inter-diffusion of Ti and Al atoms,the TiAl_(3) layer grows primarily at AA1050/TiAl_(3) interfaces.

Method of fabricating artificial rock specimens based on extrusion free forming(EFF)3D printing

Three-dimensional(3D)printing technology has been widely used to create artificial rock samples in rock mechanics.While 3D printing can create complex fractures,the material still lacks sufficient similarity to natural rock.Extrusion free forming(EFF)is a 3D printing technique that uses clay as the printing material and cures the specimens through high-temperature sintering.In this study,we attempted to use the EFF technology to fabricate artificial rock specimens.The results show the physico-mechanical properties of the specimens are significantly affected by the sintering temperature,while the nozzle diameter and layer thickness also have a certain impact.The specimens are primarily composed of SiO_(2),with mineral compositions similar to that of natural rocks.The density,uniaxial compressive strength(UCS),elastic modulus,and tensile strength of the printed specimens fall in the range of 1.65–2.54 g/cm3,16.46–50.49 MPa,2.17–13.35 GPa,and 0.82–17.18 MPa,respectively.It is capable of simulating different types of rocks,especially mudstone,sandstone,limestone,and gneiss.However,the simulation of hard rocks with UCS exceeding 50 MPa still requires validation.

Roughness characterization and shearing dislocation failure for rock-backfill interface

Shearing dislocation is a common failure type for rock–backfill interfaces because of backfill sedimentation and rock strata movement in backfill mining goaf.This paper designed a test method for rock–backfill shearing dislocation.Using digital image techno-logy and three-dimensional(3D)laser morphology scanning techniques,a set of 3D models with rough joint surfaces was established.Further,the mechanical behavior of rock–backfill shearing dislocation was investigated using a direct shear test.The effects of interface roughness on the shear–displacement curve and failure characteristics of rock–backfill specimens were considered.The 3D fractal dimen-sion,profile line joint roughness coefficient(JRC),profile line two-dimensional fractal dimension,and the surface curvature of the frac-tures were obtained.The correlation characterization of surface roughness was then analyzed,and the shear strength could be measured and calculated using JRC.The results showed the following:there were three failure threshold value points in rock–backfill shearing dis-location:30%–50%displacement before the peak,70%–90%displacement before the peak,and 100%displacement before the peak to post-peak,which could be a sign for rock–backfill shearing dislocation failure.The surface JRC could be used to judge the rock–backfill shearing dislocation failure,including post-peak sliding,uniform variations,and gradient change,corresponding to rock–backfill disloca-tion failure on the field site.The research reveals the damage mechanism for rock–backfill complexes based on the free joint surface,fills the gap of existing shearing theoretical systems for isomerism complexes,and provides a theoretical basis for the prevention and control of possible disasters in backfill mining.

A statistical damage-based constitutive model for shearing of rock joints in brittle drop mode

Some rock joints exhibit significant brittleness,characterized by a sharp decrease in shear stress upon reaching the peak strength.However,existing models often fail to accurately represent this behavior and are encumbered by numerous parameters lacking clear mechanical significance.This study presents a new statistical damage constitutive model rooted in both damage mechanics and statistics,containing only three model parameters.The proposed model encompasses all stages of joint shearing,including the compaction stage,linear stage,plastic yielding stage,drop stage,strain softening stage,and residual strength stage.To derive the analytical expression of the constitutive model,three boundary conditions are introduced.Experimental data from both natural and artificial rock joints is utilized to validate the model,resulting in average absolute relative errors ranging from 3%to 8%.Moreover,a comparative analysis with established models illustrates that the proposed model captures stress drop and post-peak strain softening more effectively,with model parameters possessing clearer mechanical interpretations.Furthermore,parameter analysis is conducted to investigate the impacts of model parameters on the curves and unveil the relationship between these parameters and the mechanical properties of rock joints.Importantly,the proposed model is straightforward in form,and all model parameters can be obtained from direct shear tests,thus facilitating the utilization in numerical simulations.

Engineering behaviour of in situ cored deep cement mixed marine deposits subjected to undrained and drained shearing

The deep cement mixing(DCM)is used to improve the capacity and reduce the settlement of the soft ground by forming cemented clay columns.The investigation on the mechanical behaviour of the DCM samples is limited to either laboratory-prepared samples or in-situ samples under unconfined compression.In this study,a series of drained and undrained triaxial shearing tests was performed on the in-situ cored DCM samples with high cement content to assess their mechanical behaviours.It is found that the drainage condition affects significantly the stiffness,peak and residual strengths of the DCM samples,which is mainly due to the state of excess pore water pressure at different strain levels,i.e.being positive before the peak deviatoric stress and negative after the peak deviatoric stress,in the undrained tests.The slope of the failure envelope changes obviously with the confining pressures,being steeper at lower stress levels and flatter at higher stress levels.The strength parameters,effective cohesion and friction angle obtained from lower stress levels(c′0 andφ′0)are 400 kPa and 58°,respectively,which are deemed to be true for design in most DCM applications where the in-situ stress levels are normally at lower values of 50-200 kPa.Additionally,the computed tomography(CT)scanning system was adopted to visualize the internal structures of DCM samples.It is found that the clay pockets existing inside the DCM samples due to uneven mixing affect markedly their stress-strain behaviour,which is one of the main reasons for the high variability of the DCM samples.

Designing new low alloyed Mg-RE alloys with high strength and ductility via high-speed extrusion

Two new low-alloyed Mg-2RE-0.8Mn-0.6Ca-0.5Zn(wt%,RE=Sm or Y)alloys are developed,which can be produced on an in-dustrial scale via relatively high-speed extrusion.These two alloys are not only comparable to commercial AZ31 alloy in extrudability,but also have superior mechanical properties,especially in terms of yield strength(YS).The excellent extrudability is related to less coarse second-phase particles and high initial melting point of the two as-cast alloys.The high strength-ductility mainly comes from the formation of fine grains,nano-spaced submicron/nano precipitates,and weak texture.Moreover,it is worth noting that the YS of the two alloys can maintain above 160 MPa at elevated temperature of 250°C,significantly higher than that of AZ31 alloy(YS:45 MPa).The Zn/Ca solute segregation at grain boundaries,the improved heat resistance of matrix due to addition of RE,and the high melting points of strengthening particles(Mn,MgZn_(2),and Mg-Zn-RE/Mg-Zn-RE-Ca)are mainly responsible for the excellent high-temperature strength.

Role of extrusion rate on the microstructure and tensile properties evolution of ultrahigh-strength low-alloy Mg-1.0Al-1.0Ca-0.4Mn(wt.%)alloy

Mg-1.0Al-1.0Ca-0.4Mn(AXM1104, wt.%) low alloy was extruded at 200 ℃ with an extrusion ratio of 25 and different ram speeds from 1.0 to 7.0 mm/s. The influence of extrusion rate on microstructure and mechanical properties of the AXM1104 alloy was systematically studied. With the increasing of extrusion rate, the mean dynamically recrystallized(DRXed) grain size of the low alloy and average particles diameter of precipitate second phases were increased, while the degree of grain boundary segregation and the intensity of the basal fiber texture were decreased. With the rising of extrusion rate from 1.0 to 7.0 mm/s, the tensile yield strength(TYS) of the as-extruded AXM1104 alloy was decreased from 445 MPa to 249 MPa, while the elongation to failure(EL) was increased from 5.0% to 17.6%. The TYS, ultimate tensile strength(UTS) and EL of the AXM1104 alloy extruded at the ram speed of 1.5 mm/s was 412 MPa, 419 MPa and 12.0%, respectively,exhibiting comprehensive tensile mechanical properties with ultra-high strength and excellent plasticity. The ultra-high TYS of 412 MPa was mainly due to the strengthening from ultra-fine DRXed grains with segregation of solute atoms at grain boundaries. The strain hardening rate is increase slightly with increasing extrusion speed, which may be ascribed to the increasing mean DRXed grain size with rising extrusion speed. The higher strain hardening rate contributes to the higher EL of these AXM1104 samples extruded at higher ram speed.

Difference in extrusion temperature dependences of microstructure and mechanical properties between extruded AZ61 and AZ91 alloys

The effects of extrusion temperature on the microstructure and tensile properties of extruded AZ61 and AZ91 alloys are investigated by subjecting them to hot extrusion at 300 and 400℃.Although the average grain size of the extruded AZ61 alloy slightly increases from 9.5 to 12.6μm with increasing extrusion temperature,its resultant microstructural variation is insignificant.In contrast,the average grain size of the extruded AZ91 alloy significantly increases from 5.7 to 22.5μm with increasing extrusion temperature,and the type of Mg17Al12 precipitates formed in it changes from fine dynamic precipitates with a spherical shape to coarse static precipitates with a lamellar structure.As the extrusion temperature increases,the tensile yield strength of the extruded AZ61 alloy increases from 183 to 197 MPa while that of the extruded AZ91 alloy decreases from 232 to 224 MPa.The tensile elongations of the extruded AZ61 and AZ91 alloys decrease with increasing extrusion temperature,but the degree of decrease is significant in the latter alloy.These different extrusion temperature dependences of the tensile properties of the extruded AZ61 and AZ91 alloys are discussed in terms of their microstructural characteristics,strengthening mechanisms,and crack initiation sites.

Mechanism of plasticity enhancement of AZ31B magnesium alloy sheet by accumulative alternating back extrusion

Accumulative alternating back extrusion was a potential fine-grain modification method.In this paper,it was an innovative attempt to develop high-performance magnesium alloy sheet by this process.Under the condition of 350 K,commercial AZ31 magnesium alloy was made into billet by accumulative alternating back extrusion,and then extruded into fine-grain magnesium alloy sheet.Through a systematic study of its microstructure and mechanical properties,the results showed that the initial state had an important influence on the evolution of the structure during extrusion.After accumulative alternating back extrusion to produce the billet,the grain size of the sheet obtained by extrusion was significantly refined,which was related to the accumulation of deformation and grain refinement during the alternating loading process.Grain refinement caused the proportion of dynamic recrystallization inside the sheet with 2 cycles of accumulative alternating back extrusion to drop to 27%.With the increase of extrusion cycles from 2 to 4,the high density of dislocations led to an increase in the proportion of dynamic recrystallization and finer grains.The texture changed from strong basal texture to weak bimodal texture.The results of uniaxial tensile test show that due to grain refinement and texture change,the yield strength was significantly reduced,and the plasticity was significantly improved.It was verified that accumulative alternating back extrusion was meaningful for subsequent processing,and it also provided scientific guidance for the development of fine-grained magnesium alloy sheet.

Variations in dynamic recrystallization behavior and mechanical properties of AZ31 alloy with extrusion temperature

This study investigates the effects of extrusion temperature on the dynamic recrystallization(DRX)behavior of a Mg-3Al-1Zn-0.3Mn(AZ31,wt%)alloy during hot extrusion and on the microstructural characteristics and mechanical properties of materials extruded at 350 and 450℃.An increase in the extrusion temperature causes a decrease in the amount of strain energy accumulated in the material during extrusion,because of promoted activation of pyramidal<c+a>slip and dynamic recovery.This reduced strain energy weakens the DRX behavior during extrusion,which eventually results in a decrease in the area fraction of recrystallized grains of the extruded material.The material extruded at 450℃has coarser grains and a stronger basal fiber texture than that extruded at 350℃.As the extrusion temperature increases from 350 to 450℃,the tensile yield strength(TYS)of the extruded material increases from 191.8 to 201.5 MPa,whereas its compressive yield strength(CYS)decreases from 122.5 to 111.0 MPa;consequently,its tension-compression yield stress ratio(CYS/TYS)decreases from 0.64 to 0.55.The increase in the TYS is attributed mainly to the stronger texture hardening and strain hardening effects of the extruded material,and the decrease in the CYS is attributed to the reduced twinning stress resulting from grain coarsening and texture intensification.The microstructural and textural evolutions of the materials during extrusion and the deformation and hardening mechanisms of the extruded materials are discussed in detail.

Advanced strategies in the application of gelatin-based bioink for extrusion bioprinting

The significance of bioink suitability for the extrusion bioprinting of tissue-like constructs cannot be overemphasized.Gelatin,derived from the hydrolysis of collagen,not only can mimic the extracellular matrix to immensely support cell function,but also is suitable for extrusion under certain conditions.Thus,gelatin has been recognized as a promising bioink for extrusion bioprinting.However,the development of a gelatin-based bioink with satisfactory printability and bioactivity to fabricate complex tissue-like constructs with the desired physicochemical properties and biofunctions for a specific biomedical application is still in its infancy.Therefore,in this review,we aim to comprehensively summarize the state-of-the-art methods of gelatin-based bioink application for extrusion bioprinting.Wefirstly outline the properties and requirements of gelatin-based bioinks for extrusion bioprinting,highlighting the strategies to overcome their main limitations in terms of printability,structural stability and cell viability.Then,the challenges and prospects are further discussed regarding the development of ideal gelatin-based bioinks for extrusion bioprinting to create complex tissue-like constructs with preferable physicochemical properties and biofunctions.

Bimodal grain structure formation and strengthening mechanisms in Mg-Mn-Al-Ca extrusion alloys

The effects of small additions of calcium (0.1%and 0.5%~1) on the dynamic recrystallization behavior and mechanical properties of asextruded Mg-1Mn-0.5Al alloys were investigated.Calcium microalloying led to the formation of Al_(2)Ca in as-cast Mg-1Mn-0.5Al-0.1Ca alloy and both Mg_(2)Ca and Al_(2)Ca phases in Mg-1Mn-0.5Al-0.5Ca alloy.The formed Al_(2)Ca particles were fractured during extrusion process and distributed at grain boundary along extrusion direction (ED).The Mg_(2)Ca phase was dynamically precipitated during extrusion process,hindering dislocation movement and reducing dislocation accumulation in low angle grain boundaries (LAGBs) and hindering the transformation of high density of LAGBs into high angle grain boundaries (HAGBs).Therefore,a bimodal structure composed of fine dynamically recrystallized (DRXed) grains and coarse un DRXed regions was formed in Ca-microalloyed Mg-1Mn-0.5Al alloys.The bimodal structure resulted in effective hetero-deformation-induced (HDI) strengthening.Additionally,the fine grains in DRXed regions and the coarse grains in un DRXed regions and the dynamically precipitated Mg_(2)Ca phase significantly enhanced the tensile yield strength from 224 MPa in Mg-1Mn-0.5Al to335 MPa and 352 MPa in Mg-1Mn-0.5Al-0.1Ca and Mg-1Mn-0.5Al-0.5Ca,respectively.Finally,a yield point phenomenon was observed in as-extruded Mg-1Mn-0.5Al-x Ca alloys,more profound with 0.5%Ca addition,which was due to the formation of (■) extension twins in un DRXed regions.

EXPERIMENTS AND SIMULATIONS OF A NEW DEVELOPED FORMING TECHNOLOGY-SHEAR-EXTRUSION PROCESS OF COMPONENTS WITH BRANCHES

Shear-extrusion process and its forming parameters are proposed, whilst its laborsaving characteristic is utilized to forge large-size shutoff valve bodies on the middle-due press. This new process is intended for the manufacture of large-size forged tubular components with branches on the middle-due press. Experiments are carried out and processing parameters are obtained regarding the shear- extrusion process of a large-size shutoff valve body. Deformation and metal flow in the shear- extrusion process are investigated. In order to verify the laborsaving characteristic of this new process, some contrast experiments of extrusion force are performed between shear-extrusion and upsetting-extrusion for forming tubular components with branches. Based on rigid-plastic FEM, a plane-strain model is established to analyze shear-extrusion process of tubular components with branches. The analysis results by 2-dimensions FEM are comparatively well consistent with experimental results. Both simulated and experimental results show that this new forming process is feasible for forging large-size tubular components with branches on the middle-due press.