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Mechanisms in Aluminum
Extrusion
Authors: A.F.M Arif, A.K. Sheikh, S.Z. Quamar
Received: November 27, 2001
Published By: Journal of Materials Processing Technology,
Liner:
Dummy
Stem:
Die
DiePressure
isProvides
Bolster:
Ring:
ItDie Pad:
Pad:
fitted
and
Holds Floating
protection
ProvidesTransfers
Tooling
with
Die:
thethe
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thefitted
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the
Configuration
support
Produces
main ram
feederextrusion
in front
to the
the
to thermal
force
for
plateof load
the
extrusion
diehot and
against
the
and stem.
from
mechanical
extrusion
billet
the
shape. the
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collapse
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of protects
bolster
backer
orthestresses
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thethe
fracture.
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to
life
pressure
the
of large
Transfers thethe
costly
plate
and expensive
stem.
and also
extrusion loadguards
container.
from theagainst
die tobolster deflection.
the pressure ring.
Configuration of a Typical Die
Hollow Dies
Solid Dies
Semi-Hollow Dies
Fracture Wear
77% Miscellaneous Mandrel 33%
3% 3%
1. Due to lack of mandrel, 1. Since a large majority of
forces at the die are far Mixed
2% Fracture the hollow dies were simple
less wear critical. 34% in geometry, there was far
2. This would indicate Deflection less of a contribution due to
lower heat of friction 29% fracture.
deformation.
Wear
29%
OUTLINE
Introduction
Profileterminology / Die Profiles
Overall and class-wise break-up of failure
modes
Various complexity failure analysis
Shape-wise breakdown of each failure
mode
Conclusion / References
Shape-Wise Breakdown
Fracture Failure Occurance Wear Failure Occurance
Miscellaneous Failure Occurance
Semi-Hollow
Semi-Hollow
12% 19% Solid
Semi-Hollow
25%
1. Additional friction, 26%
1. Since
Plastic contributions
Deformation Occuranceof the 1. This confirms the
hollow and semi-hollow dies Mandrel Failure Occurance previous
Mixed conclusion
Failure Occurance that
Solid
are almost equally
6% smalll, it hollow dies fail primarily
Semi-Hollow
7%
Semi-Hollow
26%
shows that the predominant Semi-Hollow
through wear. Solid
24%
failure for solid dies is 18% 2. Why are the solid and
fatigue fracture. semi-hollow dies about
the same even though
one has a mandral and
the other does not?
Hollow Hollow
Hollow
68% 82% 69%
OUTLINE
Introduction
Profileterminology / Die Profiles
Overall and class-wise break-up of failure
modes
Various complexity failure analysis
Shape-wise breakdown of each failure
mode
Conclusion / References
Conclusions
Testing supported the fact that the predominant failure
for solid dies is fatigue fracture.
Hollow dies fail primarily by wear.
Additional friction, temperatures and forces at the
bearing inlet due to the presence of the mandrel and re-
weld chambers in hollow dies are the reason for the
large proportion of deflection failures associated with
hollow dies.
Mixed mode failure is prevalent with hollow dies.
Miscellaneous failure is predominant with solid dies.
Mandrel failure was obviously dominant in hollow dies.
Flaws in Technical Paper
Very few shape complexities were incorporated
in the study.
Only one material type die, and one material
type billet was tested.
Time line failure wasnt included to incorporate
the data with useful economics.
There variety of hollow dies used in the test
didnt have many details, and could bias the test
data.
Refrences
[1] I. Flitta, T. Sheppard, Nature of friction in extrusion [8] M Gupta, R. Sikand, A.K. Gupta, Scr. Metallurgy Material,
process and its effect on material flow, Materials Science (1994), 30, 1343-1348.
and Technology, December (2002) 837-846. [9] M. C. Shaw and J. P. Avery, Forming limits reliablilty,
[2] Dinesh Damodaran, Rajiv Shivpuri, Prediction and stress analysis and failure prevention methods in mechanical
control of part distortion during the hot extrusion of design, ASME Centennial Bound Volume, 297-303, (1980),
titanium alloys, Journal of Materials Processing Century Publications.
Technology, 150 (2004) 70-75.
[3] Zubear Ahmed Khan, Uday Chakkingal, P. Venugopal,
Analysis of forming loads, microstructure development and
mechanical property evolution during equal channel angular
extrusion of a commercial grade aluminum alloy, Journal of
Materials Processing Technology, 135 (2003) 59-67.
[4] S. Malayappan, R. Narayanasamy, Barrelling of
aluminum solid cylinders during cold upset forging with
constraint at one end, Materials Science and Technology,
June (2002) 507-511.
[5] S. C. V. Lim, M. Gupta, Enhancing modulus and Ductility
of Mg/SiC composite through judicious selection of
extrusion temperature and heat treatment, Materials
Science and Technology, August (2002) 803-808.
[6] Bruce Chalmers, Physical Metallurgy, 321-327,
332,1959, John Wiley and Sons.
[7] F. J. Humphreys, W. S. Miller, M. R. Djazeb, Materials
Science and Technology, (1990), 6, 1157-1166.
Questions?