FEM Simulation of Surface Micro-Groove Structure Fins Produced by Cryogenic-Temperature Extrusion Machining

Abstract

In the process of metal cutting, a large amount of chips that are difficult to reuse will be produced, resulting in resource waste. As a novel metal forming process, cryogenic-temperature extrusion machining (CT-EM) can directly process chips into usable fins with a surface micro-groove structure, which has the advantage of high efficiency, energy saving and flexibility. In this study, the effects of four parameters (compression ratio λ, rake angle of the tool α, friction coefficient μ and the constraining tool corner radius R) on the effective stress, temperature and formability of micro-groove fins produced by CT-EM and room-temperature extrusion machining (RT-EM) are investigated. The results show that the maximum effective stress and formability of CT-EM are larger than that of RT-EM, which indicates that CT-EM has greater advantages in the preparation of micro-groove fins. At a λ of 0.7, the formability of CT-EM is the best. Reducing the λ and α, or increasing the μ, can improve the forming effect of the fins. CT-EM can produce micro-groove fins with the best formability when λ = 0.7, α = 5°, μ = 0.75 and R = 0.1 mm.