Improving the shape and dimensional accuracy of hollow semi-finished products during hot reverse extrusion from square workpieces

Authors

DOI:

https://doi.org/10.20535/2521-1943.2024.8.3(102).297388

Keywords:

finite element method, hot deposition, reverse extrusion, square workpiece, hollow semi-finished product, temperature, forces, stresses, deformations

Abstract

Stamping of round hollow semi-finished products by hot reverse extrusion from round and square workpieces is the first stamping step in the manufacture of hollow products for special purposes. These products require certain mechanical properties along the wall height and in the bottom part, which can be achieved by working out the metal structure by plastic deformation. The bottom part is worked out by reverse extrusion. The wall properties are obtained in the following stages of drawing the semi-finished product with thinning after extrusion. The use of square workpieces results in more intensive working out of the bottom of the semi-finished products during the reverse extrusion. However, as a result of extrusion, four protrusions appear at the end of the semi-finished product wall in places that match the corner areas of the workpiece. The presence of protrusions leads to the need for an additional operation of cutting the end of the semi-finished product before extrusion, as well as to an increase in metal usage. Therefore, an urgent task is to study the method of eliminating protrusions in the semi-finished product and the additional cutting operation.
To improve the accuracy of the shape and size of hollow semi-finished products during hot reverse extrusion from square workpieces.
Elimination of protrusions is achieved by forming chamfers in the corner zones of the square workpiece by preliminary deposition before extrusion.
The finite element method (FEM) was used to model the processes of hot deposition of corner zones on a square workpiece and subsequent reverse extrusion with the dispensing of round hollow semi-finished products. The dimensions of the chamfers on the high-carbon steel workpiece were determined, which ensured the elimination of protrusions at the end of the wall of the round semi-finished product after extrusion. The dependence of the deposition and extrusion forces on the punch movement was determined. The specific forces on the deforming tool were determined. The distributions of stresses, strains, and temperature in the deformed metal at the end of deposition and extrusion are presented. The working out of the metal structure by hot plastic deformation is evaluated. The design of a stamp for deposition and extrusion is developed.
The geometry of a square workpiece with chamfers in the corner zones was determined, which ensures the elimination of protrusions at the wall end during hot reverse extrusion with the dispensing of round hollow semi-finished products

References

  1. E. I. Sеmenov Ed., Forging and stamping. Handbook. In 4 Vol., vol. 2, Hot stamping. Moscow: Mechanical Engineering. 1986.
  2. V. N. Danchenko, A. A. Milenin and V. I. Kuzmenko, Computer modeling of metal pressure processing processes. Numerical methods. Dnipropetrovsk: System Technologies. 2008.
  3. V. L. Kalyuzhny, L. I. Aliyeva, I. S. Aliev and V. N. Gornostay, “Hot volumetric stamping of hollow products from high-strength aluminum alloy with specified mechanical properties,” Procurement production, Vol. 12, pp. 18–25, 2018.
  4. X Hu, R B Mei, F Zhu, Y Fan, Y B Liang, X B Wang, D G Wang and Z R Jing, “Numerical Simulation for Microstructure Evolution in In718 Alloy During Cylindrical Cup Backward Extrusion,” Northeastern University at Qinhuangdao Branch, Northeastern University, Qinhuangdao 066004, China, Vol. 650, pp. 92–97, 2013. DOI: 10.4028/www.scientific.net/AMR.650.92.
  5. S. Zota, S. Mróz, A. Stefanik, K. Laber and R. Mola, Theoretical and experimental analysis of the backward extrusion process with a rotational die of AZ31 alloy / Metabk 60 (2021) 1–2, pр. 36–38.
  6. S. H. Hosseini, K. Abrinia and G. Faraji, “Applicability of a modified backward extrusion process on commercially pure alumin-ium,” Materials and Design, Vol. 65, pp. 521–528, 2015. DOI: 10.1016/j.matdes.2014.09.043.
  7. S. Kuhnke, V. Sanabria, F. Gensch, R. Nitschke and S. Mueller, “Numerical Investigations on Material Flow During Indirect Extrusion of Copper-Clad Aluminum Rods,” Front. Mater., Vol. 7, Article 157, pp. 1–10, June 2020, doi: 10.3389/fmats.2020.00157
  8. Jong-Taek Yeom, Jeoung Han Kim, Jae-Keun Hong, Nho-Kwang Park and Chong Soo Lee, “Prediction of Microstructure Evo-lution in Hot Backward Extrusion of Ti-6Al-4V Alloy / Hindawi Publishing Corporation,” Journal of Metallurgy, Vol. 2012, Article ID 989834, pp. 1–6, doi:10.1155/2012/989834
  9. R. Broomand, A. Babaei, H. M. Bashiri and M. H. Zaheri, “Processing MMC tubes via friction stir backward extrusion,” Quar-terly Scientific Journal of Technical and Vocational University, Department of Mechanical Engineering, Faculty of Mechanical and Aerospace Engineering, Vol. 19, Issue 1 – Serial, No. 57, pp. 225–242, July 2022. DOI:10.48301/KSSA.2021.287462.1550.
  10. Duk Jae Yoon, Eung-Zu Kim, Kyoung Hoan Na, Yong-Shin Lee, A study on the forming characteristics of AZ 31B Mg Alloy in a combined Forward–backward extrusion at warm temperatures / MDPI, Received: 15 October 2018; Accepted: 2 November 2018; Published: 8 November 2018. pp. 1–10. DOI:10.3390/app8112187.
  11. V. Kaliuzhnyi, S. Sytnyk and V. Levchenko, “Comparative analysis of hot reverse extrusion of hollow products from round and square blanks,” Mech. Adv. Technol., Vol.7, No. 2, pp. 236–242, 2023, doi: 10.20535/2521-1943.2023.7.2.288484.
  12. O. Kaliuzhnyi, V. Kaliuzhnyi, S. Sytnyk, K. Shulga and M. “Gotra Increase in work by plastic deformation of the walls and the bottom part of the hollow semi-finished product during hot reverse extrusion,” Scientific notes. Interuniversity collection, Vol. 76, pp. 72–80, 2023, doi: 10.36910/775.24153966.

Downloads

Published

2024-09-30

How to Cite

[1]
V. Dragobetskyi, O. Kaliuzhnyi, V. Kaliuzhnyi, and S. Sytnyk, “Improving the shape and dimensional accuracy of hollow semi-finished products during hot reverse extrusion from square workpieces”, Mech. Adv. Technol., vol. 8, no. 3(102), pp. 256–264, Sep. 2024.

Issue

Vol. 8 No. 3(102) (2024)

Section

Mechanics

License

Copyright (c) 2024 Володимир Драгобецький, Олександр Калюжний, Володимир Калюжний, Станіслав Ситник

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

The ownership of copyright remains with the Authors.
 
Authors may use their own material in other publications provided that the Journal is acknowledged as the original place of publication and National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” as the Publisher.

Authors who publish with this journal agree to the following terms:

  1. Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under CC BY 4.0 that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.

  2. Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.

  3. Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work