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Title: 3D FEM Geometry and Material Flow Optimization of Porthole-Die Extrusion

Abstract

The aim of this work is to design and to improve the geometry of a porthole-die for the production of aluminum components by means of 3D FEM simulations. In fact, the use of finite element models will allow to investigate the effects of the die geometry (webs, extrusion cavity) on the material flow and on the stresses acting on the die so to reduce the die wear and to improve the tool life. The software used to perform the simulations was a commercial FEM code, Deform 3D. The technological data introduced in the FE model have been furnished by METRA S.p.A. Company, partner in this research. The results obtained have been considered valid and helpful by the Company for building a new optimized extrusion porthole-die.

Authors:
;  [1];  [2]
  1. Department of Mechanical and Industrial Engineering, University of Brescia, Via Branze 38, 25123 Brescia (Italy)
  2. Department of Design and Technology, University of Bergamo, Viale Marconi 5, 24044 Dalmine (Italy)
Publication Date:
OSTI Identifier:
21057398
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM '07: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740847; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALUMINIUM; ALUMINIUM ALLOYS; COMPUTERIZED SIMULATION; D CODES; DESIGN; ENGINEERING; EXTRUSION; FINITE ELEMENT METHOD; OPTIMIZATION; STRESSES; THREE-DIMENSIONAL CALCULATIONS; WEAR

Citation Formats

Ceretti, Elisabetta, Mazzoni, Luca, and Giardini, Claudio. 3D FEM Geometry and Material Flow Optimization of Porthole-Die Extrusion. United States: N. p., 2007. Web. doi:10.1063/1.2740847.
Ceretti, Elisabetta, Mazzoni, Luca, & Giardini, Claudio. 3D FEM Geometry and Material Flow Optimization of Porthole-Die Extrusion. United States. doi:10.1063/1.2740847.
Ceretti, Elisabetta, Mazzoni, Luca, and Giardini, Claudio. Thu . "3D FEM Geometry and Material Flow Optimization of Porthole-Die Extrusion". United States. doi:10.1063/1.2740847.
@article{osti_21057398,
title = {3D FEM Geometry and Material Flow Optimization of Porthole-Die Extrusion},
author = {Ceretti, Elisabetta and Mazzoni, Luca and Giardini, Claudio},
abstractNote = {The aim of this work is to design and to improve the geometry of a porthole-die for the production of aluminum components by means of 3D FEM simulations. In fact, the use of finite element models will allow to investigate the effects of the die geometry (webs, extrusion cavity) on the material flow and on the stresses acting on the die so to reduce the die wear and to improve the tool life. The software used to perform the simulations was a commercial FEM code, Deform 3D. The technological data introduced in the FE model have been furnished by METRA S.p.A. Company, partner in this research. The results obtained have been considered valid and helpful by the Company for building a new optimized extrusion porthole-die.},
doi = {10.1063/1.2740847},
journal = {AIP Conference Proceedings},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}
  • Abstract In the present study, response surface method (RSM) and genetic algorithm (GA) were used to study the effects of process variables like screw speed, rpm (x1), L/D ratio (x2), barrel temperature ( C; x3), and feed mix moisture content (%; x4), on flow rate of biomass during single-screw extrusion cooking. A second-order regression equation was developed for flow rate in terms of the process variables. The significance of the process variables based on Pareto chart indicated that screw speed and feed mix moisture content had the most influence followed by L/D ratio and barrel temperature on the flow rate.more » RSM analysis indicated that a screw speed>80 rpm, L/D ratio> 12, barrel temperature>80 C, and feed mix moisture content>20% resulted in maximum flow rate. Increase in screw speed and L/D ratio increased the drag flow and also the path of traverse of the feed mix inside the extruder resulting in more shear. The presence of lipids of about 35% in the biomass feed mix might have induced a lubrication effect and has significantly influenced the flow rate. The second-order regression equations were further used as the objective function for optimization using genetic algorithm. A population of 100 and iterations of 100 have successfully led to convergence the optimum. The maximum and minimum flow rates obtained using GA were 13.19 10 7 m3/s (x1=139.08 rpm, x2=15.90, x3=99.56 C, and x4=59.72%) and 0.53 10 7 m3/s (x1=59.65 rpm, x2= 11.93, x3=68.98 C, and x4=20.04%).« less
  • Screw extrusion of aluminum is a new process for production of aluminum profiles. The commercial potential could be large. Little experimental and numerical work has been done with respect to this process.The material flow of hot aluminum in a screw extruder has been analyzed using finite element formulations for the non-Newtonian Navier-Stokes equations. Aluminum material properties are modeled using the Zener-Holloman material model. Effects of stick-slip conditions are investigated with respect to pressure build up and mixing quality of the extrusion process.The numerical results are compared with physical experiments using an experimental screw extruder.