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Guoqun Zhao – One of the best experts on this subject based on the ideXlab platform.

  • evaluation of a pyramid die extrusion for a hollow Aluminum Profile using fe simulation
    Journal of Mechanical Science and Technology, 2015
    Co-Authors: Liang Chen, Guoqun Zhao, Junquan Yu, Wendong Zhang

    Abstract:

    The pyramid die extrusion for a hollow Aluminum Profile was analyzed to investigate the potential of such innovative dies. For this purpose, the pyramid and conventional porthole dies were respectively designed for a given hollow Aluminum Profile. And the extrusion process was comprehensively studied by performing different types of finite element simulation, such as the analysis of steady state, transient state and billet skin tracking. The effects of pyramid angle on the evaluation parameters of extrusion, such as extrusion load, material flow, exit temperature, length of transverse weld, quality of longitudinal weld, back end defect and die stress were overall analyzed and compared with the conventional porthole die. Through this study, the advantages and shortcomings of pyramid die were well concluded, which should be important information for die designers and makers.

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  • Virtual tryout and optimization of the extrusion die for an Aluminum Profile with complex cross-sections
    The International Journal of Advanced Manufacturing Technology, 2015
    Co-Authors: Cunsheng Zhang, Guoqun Zhao, Yanjin Guan, Lanjun Wang, Peng Li

    Abstract:

    In this paper, the “trial-and-repair” process of the extrusion die is transferred from the workshop to the computer for a complex hollow Aluminum Profile used in high-speed trains. Firstly, a finite element (FE) model of the extrusion process is established with the arbitrary Lagrangian–Eulerian code HyperXtrude. To balance the material flow velocity in the die cavity, more than ten baffle plates are used and distributed in the welding chamber. Then, taking the exit velocity uniformity as the evaluating criterion, the initial extrusion die is modified by adjusting the shapes, the layout, and the heights of the baffle plates. Through a series of modifications, the velocity difference in the cross-section of the extrudate decreases significantly from 102.3 mm/s with the initial die to 26.6 mm/s with the final one. The local twisted or bent deformation of the extrudate is well controlled with the optimal die. Finally, a real extrusion die is manufactured and a practical Profile is extruded. The difference in the rib thickness of the Profile between the experimental measurements and desired dimensions is 0.12 mm, which satisfies the practical requirements. Moreover, the microstructures in the Profile and its ribs are examined, and no heat defects are observed in the Profile. Therefore, the virtual tryout of the extrusion die in this work are well verified, and the design rules of extrusion dies could provide theoretical guidance for practical repairs of complex extrusion dies in workshop.

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  • effects of ram velocity on pyramid die extrusion of hollow Aluminum Profile
    The International Journal of Advanced Manufacturing Technology, 2015
    Co-Authors: Liang Chen, Guoqun Zhao

    Abstract:

    During the extrusion process of Aluminum alloy, the ram velocity should be well controlled, since it is an important parameter affecting the Profile quality and extrusion productivity. The effects of ram velocity on conventional porthole die extrusion have been investigated by some researchers, while its influence on pyramid die extrusion has not been fully clarified. Thus, in this study, the pyramid die extrusion process for producing a hollow rectangular Aluminum tube was comprehensively investigated by performing analysis of steady state, transient state, and billet skin tracking. Importantly, the effects of ram velocity on some evaluation parameters of pyramid die extrusion, such as the material flow behavior, extrudate temperature, extrusion force, transverse weld, quality of longitudinal weld, and back end defect, were overall investigated. The results show that the flowing velocity, extrudate temperature, extrusion force, and welding pressure tend to increase as the increase of ram velocity, while the length of transverse weld is reduced at higher ram velocity. However, the effect of ram velocity on the back end defect is quite slight. Moreover, the advantages and shortcomings of pyramid die were also discussed by comparing with the conventional porthole die.

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Cunsheng Zhang – One of the best experts on this subject based on the ideXlab platform.

  • Virtual tryout and optimization of the extrusion die for an Aluminum Profile with complex cross-sections
    The International Journal of Advanced Manufacturing Technology, 2015
    Co-Authors: Cunsheng Zhang, Guoqun Zhao, Yanjin Guan, Lanjun Wang, Peng Li

    Abstract:

    In this paper, the “trial-and-repair” process of the extrusion die is transferred from the workshop to the computer for a complex hollow Aluminum Profile used in high-speed trains. Firstly, a finite element (FE) model of the extrusion process is established with the arbitrary Lagrangian–Eulerian code HyperXtrude. To balance the material flow velocity in the die cavity, more than ten baffle plates are used and distributed in the welding chamber. Then, taking the exit velocity uniformity as the evaluating criterion, the initial extrusion die is modified by adjusting the shapes, the layout, and the heights of the baffle plates. Through a series of modifications, the velocity difference in the cross-section of the extrudate decreases significantly from 102.3 mm/s with the initial die to 26.6 mm/s with the final one. The local twisted or bent deformation of the extrudate is well controlled with the optimal die. Finally, a real extrusion die is manufactured and a practical Profile is extruded. The difference in the rib thickness of the Profile between the experimental measurements and desired dimensions is 0.12 mm, which satisfies the practical requirements. Moreover, the microstructures in the Profile and its ribs are examined, and no heat defects are observed in the Profile. Therefore, the virtual tryout of the extrusion die in this work are well verified, and the design rules of extrusion dies could provide theoretical guidance for practical repairs of complex extrusion dies in workshop.

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  • multiobjective optimization design of porthole extrusion die using pareto based genetic algorithm
    The International Journal of Advanced Manufacturing Technology, 2013
    Co-Authors: Guoqun Zhao, Cunsheng Zhang, Hao Chen, Yanjin Guan

    Abstract:

    The extrusion die plays a crucial role in Aluminum alloy Profile production, which influences product quality and service life of extrusion die directly. In this paper, a Profile with irregular shape was taken as an analysis example, and multiobjective optimization for porthole extrusion die based on modern intelligence algorithm was carried out. Aiming at achieving the uniform velocity distribution in the cross-section of the Profile as well as decreasing the maximum stress on the extrusion die and the deflection of the mandrel, the angle between port bridges, the position of die orifice, and the height of welding chamber were considered as the design variables. Then Kriging model was established on the basis of Latin hypercube samplings, and above design variables were optimized using Pareto-based genetic algorithm. Finally, an optimal die structure is gained. Compared with the initial scheme, the velocity distribution in the extrudate was more even, and the stress on the die and the deflection of the mandrel were decreased obviously in the optimal scheme. The optimal design method for porthole die has strong commonality, thus, it could give useful guidelines for practical production of the same kind of Aluminum Profile.

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  • Numerical and experimental research on extrusion process of a three-cavity Aluminum Profile
    , 2013
    Co-Authors: Cunsheng Zhang, Guoqun Zhao, Kun Yang, Yanjin Guan

    Abstract:

    In this work, the numerical and experimental investigation on extrusion process of a three-cavity Aluminum Profile has been carried out. Firstly, the extrusion process of the Profile was simulated using FE (finite element) code Hyper Xtrude. The velocity distribution and the material flow behavior during the extrusion process have been investigated. Taking into consideration of the severe non-uniformity of the velocity distribution, a series of adjustments of the initial die structure have been taken, such as the modification of drainage channels, the introduction of baffle plates, and the variation of local bearing lengths. Experimentally, a real extrusion die was manufactured and the Aluminum Profile has been extrudated on an 80 MN extrusion press. By comparing with the nose-end of the extrudate obtained by experiments, the numerical results and die modification methods were well validated, which can provide theoretical guidelines for the die design of this kind of Profile.

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Hao Chen – One of the best experts on this subject based on the ideXlab platform.

  • multiobjective optimization design of porthole extrusion die using pareto based genetic algorithm
    The International Journal of Advanced Manufacturing Technology, 2013
    Co-Authors: Guoqun Zhao, Cunsheng Zhang, Hao Chen, Yanjin Guan

    Abstract:

    The extrusion die plays a crucial role in Aluminum alloy Profile production, which influences product quality and service life of extrusion die directly. In this paper, a Profile with irregular shape was taken as an analysis example, and multiobjective optimization for porthole extrusion die based on modern intelligence algorithm was carried out. Aiming at achieving the uniform velocity distribution in the cross-section of the Profile as well as decreasing the maximum stress on the extrusion die and the deflection of the mandrel, the angle between port bridges, the position of die orifice, and the height of welding chamber were considered as the design variables. Then Kriging model was established on the basis of Latin hypercube samplings, and above design variables were optimized using Pareto-based genetic algorithm. Finally, an optimal die structure is gained. Compared with the initial scheme, the velocity distribution in the extrudate was more even, and the stress on the die and the deflection of the mandrel were decreased obviously in the optimal scheme. The optimal design method for porthole die has strong commonality, thus, it could give useful guidelines for practical production of the same kind of Aluminum Profile.

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  • effect of extrusion stem speed on extrusion process for a hollow Aluminum Profile
    Materials Science and Engineering B-advanced Functional Solid-state Materials, 2012
    Co-Authors: Cunsheng Zhang, Guoqun Zhao, Zhiren Chen, Hao Chen

    Abstract:

    Abstract Extrusion stem speed is one of important process parameters during Aluminum Profile extrusion, which directly influences the Profile quality and choice of extrusion equipments. In this paper, the extrusion process of a thin-walled hollow Aluminum Profile was simulated by means of the HyperXtrude commercial software. Through a serial of numerical simulation, the effects of stem speed on extrusion process, such as metal flow behavior at die exit, temperature distribution, extrusion force, and welding pressure, have been investigated. The numerical results showed that there existed an optimum value of stem speed for flow velocity distribution. With the increasing stem speed, the temperature of the extrudate and required extrusion force increased, and the welding quality of extrudate would be improved. Through comprehensive comparison and analysis, the appropriate stem speed could be determined for practical extrusion production. Thus, the research results could give effective guideline for determining initial billet and die temperature and choosing the proper extrusion press in Aluminum Profile industry.

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  • Optimization of an Aluminum Profile extrusion process based on Taguchi’s method with S/N analysis
    The International Journal of Advanced Manufacturing Technology, 2012
    Co-Authors: Cunsheng Zhang, Hao Chen, Guoqun Zhao, Yanjin Guan

    Abstract:

    Taguchi’s design of experiment and numerical simulation were applied in the optimization of an Aluminum Profile extrusion process. By means of HyperXtrude, the extrusion process was simulated and the effects of process parameters on the uniformity of metal flow and on the extrusion force were investigated with the signal to noise ratio and the analysis of variance. Through analysis, the optimum combination of process parameters for uniform flow velocity distribution was obtained, with the billet diameter of 170 mm, ram speed of 2.2 mm/s, die temperature of 465°C, billet preheated temperature of 480°C, and container temperature of 425°C. Compared with the initial process parameters, the velocity relative difference in the cross-section of extrudate was decreased from 2.81% to 1.39%. In the same way, the optimum process parameters for minimum required extrusion force were gained, with the billet diameter of 165 mm, ram speed of 0.4 mm/s, die temperature of 475°C, billet preheated temperature of 495°C, and container temperature of 445°C. A 24.7% decrease of required extrusion force with optimum process parameters was realized. Through the optimization analysis in this study, the extrusion performance has been greatly improved. Finally, the numerical results were validated by practical experiments, and the comparison showed that the optimization strategy developed in this work could provide the effective guidance for practical production.

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