Beruflich Dokumente
Kultur Dokumente
Department of Materials Science and Engineering, School of Engineering, Shiraz University, Shiraz, Iran
Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University, Ahwaz, Iran
a r t i c l e
i n f o
a b s t r a c t
Article history:
In this paper a new upper-bound approach is used to analyze the tube extrusion process.
A kinematically admissible velocity eld is developed to evaluate the internal power and
the power dissipated on frictional and velocity discontinuity surfaces. The total power is
17 July 2007
optimized with respect to the die angle. The optimum die angle and the critical die angle at
which a dead zone is formed are determined. The effect of constant friction factor and reduction in area on the optimum die angle is predicted. In addition, the role of die angle on the
relative extrusion pressure is investigated. Comparison of the experimental and theoretical
Keywords:
Upper-bound theory
Tube extrusion
Optimum die angle
Friction
1.
Introduction
Extrusion is a bulk metal forming process in which the crosssectional area of a billet is reduced and changed to a desired
shape by forcing it through a die. One of the main applications
of the extrusion process is the manufacturing of seamless
tubes in a wide range of reductions and materials, known as
tube extrusion. Tube extrusion is extensively used for producing hollow complex shaped products (Moshksar and Ebrahimi,
1998, 1999; Bae and Yang, 1993a,b). It is also suitable for manufacturing of composite tubes (Chitkara and Aleem, 2001a).
Several attempts have been made to analyze the tube extrusion process, using nite elements method (FEM) (Reddy et
al., 1996), slip line method (Chitkara and Butt, 1999), slab
method (Chitkara and Aleem, 2001b) and upper-bound theory (Mehta et al., 1970; Chang and Choi, 1972; Hartley, 1973;
Altan, 1994). The upper-bound theory is the most important
analytical method that may be lead to individual equations in
metal forming analysis. Mehta et al. (1970) obtained a velocity
Corresponding author.
E-mail address: ebrahimy@shirazu.ac.ir (R. Ebrahimi).
0924-0136/$ see front matter 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.07.034
eld for tube extrusion and compared it to the experimental velocity elds using the viso-plasticity method. Chang and
Choi (1972) used the upper-bound solution for tube extrusion
through curved dies and studied the effect of die geometry and
friction. They also treated the tube extrusion process through
conical dies of small angle as an illustration. Hartley (1973)
proposed a kinematically admissible velocity eld for tube
extrusion which reduces to a kinematically admissible velocity eld for solid rods extrusion in the limit as the mandrel
diameter goes to zero. Altan (1994) assumed the straight ow
lines and proposed a deformation model for tube extrusion
through a at die.
In this paper a new upper-bound analysis is used for tube
extrusion process. A kinematically admissible velocity eld
is developed and the effect of process variables on the relative extrusion pressure is investigated. Based on this model,
the equation for optimum die angle, dead zone cone angle
and relative extrusion pressure are derived. For comparing
the theoretical results to that of experimental results, a tube
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 9 ( 2 0 0 8 ) 214220
Nomenclature
k
Lf
L0
m
Pext
r, ,
rf
2.
r = Vf
U
J=2k
V
1
dV+
2 ij ij
k v dS+
Sv
mk v dS
Sf
St
Ti vi dS (1)
(3)
rf2
r2
cos
(4)
rf (Ri + rf sin )
cos
r(Ri + r sin )
Analysis of deformation
Based on the upper-bound theory, for a rigid-plastic VonMisses material and amongst all the kinematically admissible
velocity elds, the actual one that minimizes the power
required for material deformation is expressed as
(2)
r
U
= Vf
extrusion die with an orthogonal semi-die angle and a mandrel connected to the ram is designed and used for the
experimental works.
215
r
2r2
U
= Vf 3f cos
r
r
= =
r =
1
2
r
r2
U
= Vf f3 cos
r
r
r
1 U
r
2
Vf rf
sin
=
2 r3
(5)
(6)
(7)
V
1
dV
2 ij ij
(8)
(9)
216
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 9 ( 2 0 0 8 ) 214220
4
i = 0
w
3
r0
rf
r4
3Vf2 f6
r
cos2
+
Vf2 rf4
4 r6
S =
w
sin2
k v dS
(16)
(17)
(18)
rf =
Vf =
R0 Ri
sin
(11)
Rf Ri
sin
(12)
R02 Ri2
Rf2 Ri2
V0
(13)
(R0 Rf )(R0 + Ri )
Ri
(Rf + Ri )
+20 V0
ln
R R
0
i
Rf Ri
v2 = V0 sin
(19)
(20)
f ()
(14)
R02 Ri2
Rf + Ri
V0
Ri +
cos sin
Rf
2 sin2
Ri +
cos sin
R0
2 sin2
(21)
where
1
f () =
sin2
1 cos
1+
11/12 cos +
0
S2 = 2 (R0 Ri )V0
w
3
11
1
ln
sin2 +
12
11 12
11/12
1 (11/12) sin2
(22)
(15)
217
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 9 ( 2 0 0 8 ) 214220
becomes
S =
w
mk v dS
(23)
v6 = Vf V0
(33)
rf (Ri + rf sin )
cos
r(Ri + r sin )
m0
S3 = 2 Vf cos (Ri + rf sin )rf
w
3
r0
rf
dr
r
Rf Ri
S3
w
S7 = 2 L0
(26)
Then by replacing Eqs. (29)(36) into Eq. (23) and using Eqs.
(11)(13), the power dissipated on the frictional surfaces S4 S7
can be determined as
(27)
rf
V V0
r f
dS4 = 2Ri dr
(28)
(29)
(30)
(35)
R0 Rf
tan
S4
w
m0
= 2 V0 Ri
3
S5
w
m0
= 2 V0
3
m0
S6 = 2 V0
w
3
(31)
R0
(36)
R02 Ri2
(Rf + Ri ) sin
R02 Ri2
Rf2 Ri2
R02 Rf2
Rf + Ri
(25)
R R
(R2 Ri2 )Rf
0
0
i
= 2 V0 0
(cot ) ln
Rf Ri
(Rf + Ri )
3
(34)
sin
v7 = V0
By integrating Eq. (26) and using Eqs. (11)(13), the power dissipated on the frictional surface S3 is obtained as
R R
0
i
R R
f
i
(24)
Thus:
ln
R R
0
i
Rf Ri
R0 Rf
sin
(37)
Rf Lf
(38)
1
m0
R0 Rf
S7 = 2 V0 L0
w
tan
3
Ri
(39)
R0
(40)
Based on the model, the total power needed for tube extrusion
process can be obtained by summing the internal power and
the power dissipated on all frictional and velocity discontinuity surfaces. Then
total = w
i+w
S1 + w
S2 + w
S3 + w
S4 + w
S5 + w
S6 + w
S7
w
(41)
(42)
which yields:
(mRf + mRi )((R02 Ri2 )/(Rf + Ri )) ln((R0 Ri )/(Rf Ri )) mRi (R0 Rf )
opt =
((R02 Ri2 )/(Rf + Ri ))((Ri /6) + (Rf /3)) + (R0 Ri )((Ri /6) + (Rf /3)) + (m/2)Ri ((R02 Ri2 )/(Rf + Ri )) ln((R0 Ri )/(Rf
(43)
Ri )) (m/2)Ri (R0 Rf )
In the case that a dead zone is formed, the dead zone cone
angle, 1 , is determined by
(Rf + mRi )((R02 Ri2 )/(Rf + Ri )) ln((R0 Ri )/(Rf Ri )) mRi (R0 Rf )
1 =
((R02 Ri2 )/(Rf + Ri ))((Ri /6) + (Rf /3)) + (R0 Ri )((Ri /6) + (Rf /3)) + (m/2)Ri ((R02 Ri2 )/(Rf + Ri )) ln((R0 Ri )/(Rf
(44)
Ri )) (m/2)Ri (R0 Rf )
S5 = 2Rf Lf
(32)
218
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 9 ( 2 0 0 8 ) 214220
(45)
cos sin
Rf
2 sin2
2
+
3(R0 + Ri )
+
2m
+
3 sin
2 sin2
f ()
Ri
Fig. 2 Effect of constant friction factor on the optimum
semi-cone angle, .
cos sin
R0
2 sin2
Rf Ri
2
+
3(Rf + Ri )
+
R R
0
i
2 sin2
Ri
2mRf
(cot ) ln
+
3(Rf Ri )
Ri
ln
Rf + Ri
R R
0
i
Rf Ri
R R
0
i
Rf Ri
Ri (R0 Rf )
2
R02 Ri2
2mRi R02 Rf
2mRf
Lf +
Lf
+
3(Rf2 Ri2 )
3(Rf2 Ri2 )(R02 Ri2 )
2m
+
3
3.
L0
R0 Rf
sin
R0
R02
Ri2
(46)
Experimental procedures
(MPa) = 1950.316
4.
(47)
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 9 ( 2 0 0 8 ) 214220
219
5.
Conclusions
A new upper-bound model is used to analysis the tube extrusion process and the following results are obtained:
220
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 1 9 9 ( 2 0 0 8 ) 214220
(3) With increasing the constant friction factor, the optimum cone angle increases. However, the constant friction
factor has no signicant effect on the dead zone cone
angle.
(4) With increasing the reduction in area, the optimum semicone angle increases. The effect of the reduction in area is
much more signicant at high values of constant friction
factor.
(5) For die angles larger than a critical value, crt , a dead metal
zone with a cone angle of 1 is formed on the corner of the
die.
Acknowledgment
Financial support by the ofce of Research Council of Shiraz
University through grant number 84-EN-1768-C306 is appreciated.
references