Abstract
This research deals with the forward extrusion process of tubes. In this process, a piercing process was carried out on the billet to produce the tube, followed directly by a reduction in the wall thickness. A specific geometrical shape for the piercing zone and the wall thickness reduction zone were chosen and designed. The effects of the redundant shear strain and the magnitude of the extrusion load were investigated and simulated with the finite element method using Q Form software program. Lead was used as model materials since (if the experiments were carried out at room temperature) it has the similar behavior of the steel at high temperature. The results obtained have shown that at the piercing zone, the lowest values of the extrusion load, the redundant strain, the total strain and the finite element effective strain were when a piercing tool (mandrel) of (C = 1.1) was used. While, at the die zone, the lowest values of the extrusion load, the redundant strain, the total strain was when a die of (C = 0.9) was used.
Highlights
In the materials science, deformation is a change in the shape or size of an object due to an applied force
This research deals with the forward extrusion process of tubes
Mechanical properties of the material, frictional condition at the tool—workpiece interface, extrusion ratio and die profile are among the important parameters that significantly affect the desired characteristics of the product [1]
Summary
Deformation is a change in the shape or size of an object due to an applied force. This can be a result of tensile (pulling) forces, compressive (pushing) forces, shear, bending or torsion (twisting). One of the most important factors in a forming operation is the profile of the deformation zone; it is an important parameter for optimizing a process variable, such as extrusion pressure [2]. Due to the difficulty in the manufacture of nonconical dies, most research concerned the optimization of rod extrusion die geometry, focused on conical dies [3], but in recent year due to the presence of modern machines such as the CNC machines, the curved dies were produced and used. This paper is divided into five main sections, namely: The first part is the introduction where we dealt with previous research on the subject and the basics of the extrusion process; the second part is a theoretical background, fundamentals and mathematical equations of the research topic; the third part was about the experimental equipments and procedure where we dealt with how the extrusion set were produced for the extrusion process; the fourth part dealt with the results and discussion and the fifth part was dealt with the conclusion in addition to the references
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