Computer Modeling and Analysis of the Energy-Power Process Parameters of the Combined Machining of Alloys Al-Mg System

Abstract

Article shows the results of studies of the process of combined rolling-extruding of an alloy of the Al-Mg system (AlMg6) under various temperature-speed and deformation conditions. Calculations shows that with increasing metal temperature at the entrance to the deformation center, the values ​​of the forces on the rolls and the die decrease, the increase in drawing leads to an increase in the values ​​of forces on both the rolls and the die, and an increase in the deformation rate leads to hardening of the metal and increasing energy parameters of the process of combined machining. However, the maximum extruding force on the combined machining units is 5-10 times lower than the efforts to obtain the same press products on hydraulic presses. A computer model of the combined machining process created with the help of the DEFORM 3D complex, the analysis of the metal flow is made, the temperature distribution of the metal over the section of the workpiece invstigated when producing round bars of different diameters. Shaping of the metal corresponds to the data of experimental and theoretical studies, while the deformation center has a characteristic appearance, including the gripping zones of the workpiece and its rolling, repressing and extrusion. The peculiarity for this alloy is that with a drawing ratio of μ = 3.7 and a strain rate of ξ = 0.78 s-1, the steady extruding process takes place without completely filling the deformation zone from the side of the roll with a protrusion. An increase in drawing ratio or strain rate leads to a decrease in the contactless zone or to its absence. The change in metal temperature also depends on the presence of a contactless zone, which contributes to an increase in heat transfer from the billet to the rolls. The results of the research were used to develop the technology for the production of welding wire from Al-Mg system alloys.