Finite Element Analysis of Extrusion Process for Magnesium Alloy Internal Threads with Electromagnetic Induction-Assisted Heating and Thread Performance Research.

Meng Liu,Rui Fan,Zesheng Ji,Xingguo Wang

doi:10.3390/ma13092170

Abstract

The casting magnesium alloy AZ91D cannot be extruded at room temperature. This paper presents a process for extruding internal threads using AZ91D heated by electromagnetic induction. The feasibility of the process is verified by finite element simulation and experiments. Using DEFORM-3D to simulate the process of extruding a M12 × 1.25 mm threaded hole by electromagnetic induction-assisted heating, the equivalent stress-strain and material flow law in the process of thread deformation was analyzed and verified by experiments. Three parameters—hole diameter, machine speed and heating temperature—were considered to study the influence of different process conditions on the forming torque. The results show that a heating temperature above 523 K can improve the plasticity of AZ91D. The hole diameter has an important influence on the forming torque. The forming process is not suitable for high-speed machining. The surface metal of the thread formed by this process has a strong deformation layer, which can improve the strength and hardness of the thread.

Highlights

With the development of science and technology in the 21st century, light alloy forming and manufacturing technology has made a great contribution to the development of aerospace, automobile, major equipment, energy, weapons, shipbuilding and information industries [1]
As the cold extrusion of internal threads belongs to the plastic forming category of large metal deformation, the plastic deformation is far greater than the elastic deformation, so the rigid plastic finite element method was used for analysis
The research objective of this paper is to study the AZ91D magnesium alloy

Summary

Introduction

With the development of science and technology in the 21st century, light alloy forming and manufacturing technology has made a great contribution to the development of aerospace, automobile, major equipment, energy, weapons, shipbuilding and information industries [1]. Magnesium alloy is the lightest structural metal, with a density two thirds that of aluminum and one quarter that of iron. It has high strength, rigidity, damping, machining and thermal conductivity, and a high absorption of vibration and impact. The effect of magnesium alloy on reducing automobile mass and energy consumption is significant. Magnesium and its alloy are widely used in automobile manufacturing enterprises. Magnesium alloy is used in the automobile industry instead of steel in engines, saving 0.25l/100 km fuel in carbon dioxide emissions, making the center of gravity of the automobile move backward, and improving the steering performance of the automobile [2]

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