Axisymmetric extrusion through adaptable dies—Part 1: Flexible velocity fields and power terms

Abstract

An adaptable die is one that not only produces the correct geometrical shape, but also is designed through an adaptable method to impart other desirable properties to the product or process. In this first part of a series of papers, six kinematically admissible velocity fields are developed for use in upper bound models for axisymmetric extrusion through various dies, including extrusion through adaptable dies. Three base velocity fields are presented: (1) assuming proportional angles in the deformation zone, (2) assuming proportional areas in the deformation zone, or (3) assuming proportional distances from the centerline in the deformation zone. The base velocity is modified by an additional term comprised of two functions. One function allows extra flexibility in the radial direction, and the second function allows extra flexibility in the angular direction. There are two forms of the second function, which meet the required boundary conditions. The flexibility function in the radial direction is represented by a series of Legendre polynomials, which are orthogonal over the deformation region. The power terms derived for these velocity fields for use in upper bound models are also presented. Part 2 of this series compares the results obtained in upper bound models for the six velocity fields for a spherical extrusion die. In Part 3, the use of the best velocity field for extrusion through streamlined dies is developed to determine the adaptable die shape, which minimizes the required extrusion pressure. Additionally, the adaptable die shape is compared with results from Yang and Han for arbitrarily curved and streamlined dies.