Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method
Abstract
Shear assisted processing and extrusion (ShAPE) is a solid-phase processing technique that adds an additional shear force as compared with a conventional extrusion approach. Recently, ShAPE has demonstrated the capability of extruding high-performance aluminum alloy 7075 (AA7075) tubes at speeds up to 12.2 m/min without surface tearing. However, the relationship among the ShAPE processing parameters, thermomechanical conditions, contact conditions, heat generation, and microstructure evolution remains primarily empirical because an insightful understanding of the associated physics is still lacking. To help elucidate these relationships, this work proposes a thermomechanical meshfree model for the first time for ShAPE processing of AA7075 using the smoothed particle hydrodynamics (SPH) method. The meshfree model is first validated thoroughly by experimental data in terms of material flow, die face temperature, and extrusion force with various processing parameters. The validated model is then used to analyze the steady-state contact conditions and heat generation rates during ShAPE processing. Distributions of the average grain size of AA7075 being extruded are calculated using the SPH model output. The meshfree model results reveal that extrusions conducted at lower temperatures and higher strain rates yield more refined grains and possibly higher material strength, which is also consistent with the experimental observations.
- Authors:
-
- Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
- Colorado School of Mines, Golden, CO (United States)
- Publication Date:
- Research Org.:
- Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
- Sponsoring Org.:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office; USDOE Laboratory Directed Research and Development (LDRD) Program
- OSTI Identifier:
- 1883352
- Report Number(s):
- PNNL-SA-173428
Journal ID: ISSN 0264-1275
- Grant/Contract Number:
- AC05-76RL01830
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Materials & Design
- Additional Journal Information:
- Journal Volume: 221; Journal ID: ISSN 0264-1275
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; SPPSI; shear assisted processing and extrusions (ShAPE); smoothed particle hydrodynamics; aluminum alloy 7075; stick-slip contact condition; heat generation rate
Citation Formats
Li, Lei, Reza-E-Rabby, Md, Overman, Nicole R., Wang, Tianhao, Whalen, Scott A., Grant, Glenn J., Mathaudhu, Suveen N., and Soulami, Ayoub. Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method. United States: N. p., 2022.
Web. doi:10.1016/j.matdes.2022.111010.
Li, Lei, Reza-E-Rabby, Md, Overman, Nicole R., Wang, Tianhao, Whalen, Scott A., Grant, Glenn J., Mathaudhu, Suveen N., & Soulami, Ayoub. Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method. United States. https://doi.org/10.1016/j.matdes.2022.111010
Li, Lei, Reza-E-Rabby, Md, Overman, Nicole R., Wang, Tianhao, Whalen, Scott A., Grant, Glenn J., Mathaudhu, Suveen N., and Soulami, Ayoub. Tue .
"Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method". United States. https://doi.org/10.1016/j.matdes.2022.111010. https://www.osti.gov/servlets/purl/1883352.
@article{osti_1883352,
title = {Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method},
author = {Li, Lei and Reza-E-Rabby, Md and Overman, Nicole R. and Wang, Tianhao and Whalen, Scott A. and Grant, Glenn J. and Mathaudhu, Suveen N. and Soulami, Ayoub},
abstractNote = {Shear assisted processing and extrusion (ShAPE) is a solid-phase processing technique that adds an additional shear force as compared with a conventional extrusion approach. Recently, ShAPE has demonstrated the capability of extruding high-performance aluminum alloy 7075 (AA7075) tubes at speeds up to 12.2 m/min without surface tearing. However, the relationship among the ShAPE processing parameters, thermomechanical conditions, contact conditions, heat generation, and microstructure evolution remains primarily empirical because an insightful understanding of the associated physics is still lacking. To help elucidate these relationships, this work proposes a thermomechanical meshfree model for the first time for ShAPE processing of AA7075 using the smoothed particle hydrodynamics (SPH) method. The meshfree model is first validated thoroughly by experimental data in terms of material flow, die face temperature, and extrusion force with various processing parameters. The validated model is then used to analyze the steady-state contact conditions and heat generation rates during ShAPE processing. Distributions of the average grain size of AA7075 being extruded are calculated using the SPH model output. The meshfree model results reveal that extrusions conducted at lower temperatures and higher strain rates yield more refined grains and possibly higher material strength, which is also consistent with the experimental observations.},
doi = {10.1016/j.matdes.2022.111010},
journal = {Materials & Design},
number = ,
volume = 221,
place = {United States},
year = {Tue Aug 02 00:00:00 EDT 2022},
month = {Tue Aug 02 00:00:00 EDT 2022}
}
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