Extrusion Speed Research Articles

Achieving high strength-ductility synergy in Mg-Gd-Zn-Zr alloy by controlling extrusion processes parameters

The high rare earth content in current magnesium alloys poses environmental and economic challenges. To address this issue, this study designs a Mg-7.5Gd-6Zn-0.5Zr alloy (GZ76, wt.%) with low rare earth content, high strength, and excellent ductility. The morphology of the as-cast GZ76 alloy is characterized by a dendritic structure consisting of an α-Mg matrix and interdendritic zones comprising W+I phases, interspersed with fragmentary Zn-Zr phases. Furthermore, the extrusion process is employed to meticulously control the microstructure and enhance the mechanical properties of the alloy. This research focuses on investigating the effects of extrusion parameters on magnesium alloys to optimize their extrusion processing conditions. Through systematic manipulation of the extrusion ratio and extrusion speed, a comprehensive analysis is conducted to examine their impacts on grain refinement, texture evolution, distribution of second phase, and mechanical properties of extruded magnesium alloys. The results indicate that due to the insufficient recrystallization process, the microstructure of the as-extruded GZ76 alloys exhibits a bimodal structure, encompassing both fine recrystallized grains and coarse unrecrystallized grains. At larger extrusion ratio, a faster extrusion speed leads to superior mechanical properties of the alloy. Conversely, at smaller extrusion ratio, a slower extrusion speed is more favorable for achieving higher strength. These findings provide valuable insights into optimizing the extrusion parameters for enhancing the performance of magnesium alloys in engineering applications.

Optimization of microstructure and mechanical properties of 7075 aluminum alloy by equal channel angular pressing technology

Abstract The equal channel angular pressing technology, as an effective technique for modifying the surface of a material, has had a significant impact on the microstructure and mechanical properties of the 7075 aluminum alloy. The study achieved the refinement of 7075 aluminum alloy grains and the homogenization of the second phase particle distribution through equal channel angular pressing technology, thereby significantly improving the strength and plasticity of the material. Through orthogonal experimental design, the effects of extrusion angle, extrusion speed, and remelting temperature on material properties were studied. The results showed that appropriate ECAP parameters could effectively regulate the microstructure of 7075 aluminum alloy, thereby optimizing its mechanical properties. Especially in the analysis of equivalent strain rate, when the extrusion angle was 50°, the position of the maximum equivalent strain rate at the forefront point remained unchanged, but the equivalent strain rate decreased to 0.107-1. In the aging hardness analysis, when the number of equal channel angular pressing passes was 3, the aging hardness of G group 7075 aluminum alloy increased to 195HV in the first 5 minutes. The equal channel angular pressing technology can optimize the internal structure of 7075 aluminum alloy and improve the material's plasticity and mechanical properties. The research provides important technical support for the application of 7075 aluminum alloy in high-end equipment manufacturing.

Influence of Material Extrusion Speed on Aggregate Distribution Heterogeneity in 3D Printed Concrete

Influence of Material Extrusion Speed on Aggregate Distribution Heterogeneity in 3D Printed Concrete

Texture evolution induced by extrusion parameters and its effect on strengthening-toughening mechanisms of Al-Mg-Si-Cu-Mn alloys

In this study, extrusion experiments were carried out on Al-Mg-Si-Cu-Mn alloys with different extrusion ratios (ERs), extrusion temperatures (ETs), and extrusion speeds (ESs). By using electron backscatter diffraction (EBSD) analysis, tensile testing, and other analytical means, the evolution of microstructure, texture, and properties of the extruded alloys was systematically investigated, and the strengthening-toughening mechanism induced by the extrusion parameters was revealed. It was found that the strength of the extruded alloy shows a tendency to first increase and then decrease with the increase of the ER and ES, and the ‘critical ER' and ‘critical ES' are 29.5 and 2.5 mm/s, respectively; the strength of the extruded alloy gradually increases with the increase of the ET. The alloy achieved excellent strength-toughness matching at the ER of 29.5, ET of 480 °C, and ES of 2.5 mm/s. The yield strength (YS), ultimate tensile strength (UTS), and elongation (EL) of the extruded alloy at this condition were ∼169.58 MPa, ∼314.36 MPa, and ∼16.57 %, respectively. This excellent strength-toughness matching is mainly related to the following aspects: 1) grain refinement provides high grain boundary strengthening effect and appropriate work hardening ability; 2) <111>//ED texture has a strong preferential orientation; 3) the variation trend of dislocation density is importantly related to <111>//ED and EXa{011}<111> textures; 4) Cube{001}<100> and Goss{011}<100> textures have a softening effect. The above findings provide new insights into the potential mechanisms of hot extrusion forming of aluminum alloys, which are of important guiding for the design and development of aluminum alloys with excellent strength-toughness combinations.

High-strength and high-plasticity ZK60 magnesium alloy prepared by rapid solidification and high-speed extrusion

The extrusion speed of ZK60 magnesium alloy is usually lower than 5 m/min. The rapidly solidified (RS) ZK60 magnesium alloy extruded at 350 ℃ with die-exit speeds of 10 m/min, 20 m/min and 30 m/min was investigated. The results reveal that after the RS ZK60 alloy was extruded at different die-exit speeds, the average size of dynamically recrystallized grains is 1.19–1.40 μm, the percent of high-angle grain boundaries (HAGBs) become larger with the average orientation degree of 57.83 ° to 54.81 °, the intensity of texture at (0001)<1̅100> is below 3.4, and the Schmid factors of the prismatic and pyramidal planes reach the high value of no lower than 0.42 overall, while no coarse MgZn phase was observed. The yield tensile strength, ultimate tensile strength and elongation of the RS as-extruded ZK60 magnesium alloy change slowly from 321 to 299 MPa, -355–348 MPa, and -23–27 % when the die-exit speed increase from 10 to 30 m/min, respectively. The ultra-fine grains and disappearance of the coarse low melting-point MgZn phase are the main reasons for the high-speed extrusion, high strength, high plasticity and low texture of the RS as-extruded ZK60 magnesium alloy.

Effect of Hot Extrusion on Microstructure, Texture, and Mechanical Properties of Mg-Zn-Mn-0.5Ca Alloy

This paper investigates the microstructure, texture, and mechanical properties of the Mg-4Zn-1Mn-0.5Ca alloy subjected to hot extrusion under varying conditions of temperature (260 °C, 300 °C, 340 °C) and extrusion speed (0.01 mm/s, 0.1 mm/s, 1 mm/s). The primary objective is to determine the optimal extrusion parameters within the selected experimental range for achieving superior mechanical properties. The results indicate that, when extruded at a constant speed of 0.1 mm/s, the alloy exhibits optimal performance at 340 °C, with a yield strength of 202 MPa, ultimate tensile strength (UTS) of 306 MPa, and elongation at fracture of 18.9%. A decrease in extrusion temperature leads to an increase in yield strength but a reduction in ductility. Specifically, the UTS reaches its peak at 342 MPa at 300 °C, while it drops slightly to 329 MPa at 260 °C. The final results show that the comprehensive mechanical properties of the Mg-4Zn-1Mn-0.5Ca alloy obtained by hot extrusion treatment with an extrusion temperature of 300 °C and extrusion speed of 0.1 mm/s are the best and can effectively improve the mechanical properties of the alloy and provide a good choice for the preparation of other biodegradable magnesium alloy products.

A Modelling Framework for Rapid Evaluation of Speed Limitations during Extrusion of Aluminium Profiles

Hot tearing is a well-known limitation when trying to maximize the throughput rate in aluminium extrusion. In the present work an analytical modelling framework is presented which can be used to predict the maximum extrusion speed that can be applied in production without formation of this type of surface defect. The modelling framework allows almost instantaneous estimates on the resulting productivity in terms of maximum extrusion speed. This is obtained by developing an analytical model for the maximum temperature at the die exit which incorporate the effect of alloy composition and billet processing. The results are consolidated into extrusion limit diagrams, mapping the maximum allowable extrusion speed as a function of billet pre-heat temperature, alloy composition, and homogenisation heat treatment. The calculated temperatures and extrusion limit diagrams obtained from the analytical model are compared with measured temperatures and critical extrusion speeds from extrusion tests of various 6xxx series alloys for a simple rod-shaped geometry. The comparisons indicate that the presented modelling approach gives sufficiently accurate predictions for future application in optimisation of alloy composition and process parameters in extrusion of profiles.

A new severe plastic deformation technique of combined extrusion and torsion to prepare bulk ultrafine grained copper

Reducing grain size is a well-established method for strengthening metals. In this study, a novel severe plastic deformation technique—combined extrusion and torsion (CET) with composite strain—was developed to fabricate bulk ultrafine grained metals. A single pass of CET treatment (with a rotation velocity of 1 r/s and extrusion speed of 3 mm/s) refined coarse-grained copper from 54 μm to 450 nm at room temperature, resulting a significant increase in hardness from 0.55 GPa to 1.3 GPa. The CET technique addresses the limitations of conventional extrusion-processed copper (without torsion), which suffers from gradient microstructure and hardness distribution. It provides enhanced strain accumulation under the same extrusion ratio conditions. The more homogeneous microstructures and properties of CET-processed copper rods are attributed to the reduced strain gradient due to torsion. Additionally, targeted finite element analysis indicated that the CET technology requires 37 % less extrusion load and offers at least 30 % more strain compared to conventional extrusion methods. Compared with other severe plastic deformation methods, such as equal channel angular pressing and high-pressure torsion, which involve simpler deformation processes, the CET technique shows considerable promise for large-scale manufacturing of ultrafine-grained metals.

Simulating the Rising Air Bubbles Stream through Heavy Fuel Oil Residue Bubble Column Reactor using COMSOL

Several industrial operations rely on the rise of air bubbles through heavy fuel oil residue (HFOr), including oil recovery and wastewater treatment. In order to increase efficiency and decrease expenses, it is necessary to understand the peculiarities of this process. With the help of COMSOL Multiphysics, we numerically simulate the ascent of a single air bubble via HFOr in this article. The dimensions of the container used in the simulations were (100) mm in diameter and (200) mm in height, with an air bubble diameter of 4.5 mm. For an air bubble ascending through an HFOr column, the predicted numerical outcomes are contrasted with nine experimental versions. As the bubble rose higher, the region with the greatest number of vortices was located on its side. The remaining vortex is contained inside the bubble. In addition, since drag decreases the flow, a lighter fluid usually exhibits a region of strong vortex and low pressure. Because of the oscillation effect, the results reveal that the rising velocity initially rises and then gradually falls between 0.6 and 0.65 s. The air bubbles' wavy motion is caused by the high fluid density, which becomes worse as the air velocity gets higher. The values of the drag coefficient rise sharply with decreasing air extrusion speed. It turns out that the height of the fluid has an inverse relationship with the pressure.

Microstructure and mechanical properties of a low-alloyed Mg–Zn–Al–Ca alloy: Effect of extrusion speed

A low-alloyed Mg-1.2Zn-0.6Al-0.1Ca (wt.%) alloy was extruded at 200 °C with different ram speeds (0.5–4.0 mm/s), and the microstructure and mechanical properties were studied systematically. Heterostructures with fine dynamic recrystallized (DRXed) grains and coarse unDRXed grains were achieved at lower ram speeds of 0.5 mm/s and 1.0 mm/s, and fully-DRXed microstructure was attained at 4.0 mm/s. Increasing the extrusion speed resulted in an increase in DRXed grain size from 0.9 μm to 3.8 μm, and a transformation of the DRXed texture component from <10 to 10>−<11–20> to a new orientation that deviated by approximately 14°. The sample extruded at 0.5 mm/s presented an excellent tensile yield strength (TYS) of 369 MPa along with a 7.8% elongation, which was mainly due to the high hetero-deformation induced (HDI) strengthening provided by its heterostructures. Increasing ram speed resulted in an improved elongation despite a decreased TYS. The reasons for the decreased strength with increasing extrusion speed were mainly associated with grain growth, reduced dislocation density and weakened HDI strengthening. The reasons for the improved ductility with increasing extrusion speed were largely due to the increased DRXed grains fraction with soft orientations.

Novel additive lamination manufacturing system for rapid fabrication of large-scale reinforced structural members

Purpose Additive lamination manufacturing (ALM), as a novel additive manufacturing technology, builds up the geometry via the lamination of fiber-reinforced polymer (FRP) fabric laterally, rendering it suitable for fabricating large-scale Stay-in-Place concrete formwork. This paper aims to investigate the control parameters and structure performance of ALM and assess its application for the fabrication of large-scale concrete formwork. Design/methodology/approach Based on previous feasibility studies, this research systematically investigates the control and material parameters that influence horizontal and vertical extrusion speeds, as well as the overall quality of ALM. Once the system parameters are established, a series of prototypes are fabricated and tested to validate the tensile strength of the formwork and its reinforcement capabilities. In addition, this study assesses the potential geometric freedom and implementation constraints of ALM. Findings This research identifies the essential control parameters for path planning in ALM and examines their impact on fabrication. In addition, this paper evaluates ALM’s strengths and limitations in producing concrete formwork for large-scale concrete structures, comparing these to industry benchmarks. Originality/value A critical challenge in additive manufacturing lies in its scalability and compatibility with existing construction processes. In comparison to concrete, FRP offers advantages such as being lighter, easier to handle and providing surface protection and reinforcement. These qualities make FRP superior for formwork and compatible with existing building standards. Despite its advantages and potential, the current path planning and control model in 3D printing do not apply to ALM due to its novel build-up process. Also, the performance of fabricated parts as part of integrated large-scale structures is yet to be studied.

A versatile steel belt casting equipment for in situ synchrotron radiation x-ray scattering measurement of polymer films.

A steel belt casting equipment, weighing approximately ∼6-7 tons and measuring ∼5m in length, has been designed and developed for simulating the industrial processing of polymer films and being combined with synchrotron radiation in situ x-ray scattering measurements. Through modification of its modules, it is feasible to implement two distinct film casting modes, namely the wet and the dry casting processes. The speed of a steel belt can span from 0.5 to 8 m/min. The highest experimental temperature and drying wind speed are 300 °C and 6m/s, respectively. All film casting parameters, such as extrusion speed, distance between die and steel belt, casting speed, temperature, and wind speed, can be adjusted independently. Especially, the control accuracy of the temperature and casting rate can reach ±0.1 °C and ±0.01 m/min, respectively. The feasibility of this equipment has been validated through in situ x-ray scattering tests at the BL10U1 industrial beamline of the Shanghai synchrotron radiation facility. With the assistance of this equipment, the understanding of the physical mechanism behind the film casting process should be improved so that the development of advanced functional polymer films.

Online ultrasonic monitoring of FDM nozzle temperature based on metamaterial buffer rod

Abstract Fused deposition modeling (FDM) has been widely used for fabricating parts with complex geometries. However, during the printing process the nozzle temperature fluctuates which may cause nozzle blockage, inter-filament delamination, over-melting, etc. Therefore, it is of significance to develop an online and in-situ nozzle monitoring system which could overcome such drawbacks for quality assurance. In this work, a multifunctional system is designed by incorporating a traditional ultrasonic probe and a metamaterial buffer rod to online monitor the nozzle temperature and ensure a correct extrusion force and speed. A parametric simulation model is first constructed implicitly based on thermal-acoustic metamaterial structures for the buffer rod. Secondly, since the high-fidelity calculation is computationally expensive, an efficient surrogate model with kriging approach is constructed based on the dataset drawn from limited trials for rapid prediction. Thirdly, multidisciplinary optimization is performed by the NSGA-III algorithm considering the thermal insulation performance, ultrasonic attenuation and structure integrity. The rod is fabricated according to the best parameters decided. A cross-correlation algorithm is calibrated with thermocouple measurement after waveform recording at different temperatures. The online and in-situ temperature measurement can be realized during 3D printing successfully eventually. This will help to improve the printing quality with potential feedback strategies.

Assessing the Correlation Between the Physico-Mechanical Characteristics and Microstructure of Reclaimed Carbon Dust Reinforced ABS Polymer Composite in the Extrusion Process

ABS polymer has limited stiffness and will fracture upon reaching this limit. Reinforcing ABS with reclaimed carbon dust (rCD) from CFRP waste, which has superior stiffness in both compression and tension, can prevent this failure. This study evaluates the impact of varying rCD filler content and screw extruder speeds on the physico-mechanical properties of the composite. rCD content ranges from 0 wt.% to 40 wt.% and screw speeds of 20 rpm and 40 rpm are used. The rCD was sieved and its quality was verified using particle size analysis (PSA), field emission scanning electron microscopy with energy dispersive X-ray (FESEM-EDX), and X-ray diffraction (XRD) before composite fabrication in a single screw extruder. The physico-mechanical properties, including tensile strength, Young’s modulus, and density, were tested using a universal testing machine (UTM) and Archimedes technique. All samples appeared undistorted prior to UTM evaluation. Results indicated that composites processed at 40 rpm with 40 wt.% rCD exhibited superior physico-mechanical properties compared to those processed at 20 rpm. Fractography of tensile fracture samples showed well-dispersed rCD within the ABS matrix, with minimal large pores at 40 rpm. Additionally, the highest tensile strength (31.48 MPa) and Young’s modulus (1.603 GPa) indicated good dispersion of rCD and strong interfacial bonding between the matrix and fiber. Thus, a 40 rpm screw speed is more effective for mixing ABS/rCD composites. In conclusion, rCD was successfully reclaimed and integrated into ABS, resulting in a composite with enhanced strength properties suitable for assistive medical device application.

Motor domain of condensin and step formation in extruding loop of DNA.

During the asymmetric loop extrusion of DNA by a condensin complex, one domain of the complex stably anchors to the DNA molecule, and another domain reels in the DNA strand into a loop. The DNA strand in the loop is fully relaxed, or there is no tension in the loop. Just outside of the loop, there is a tension that resists the extrusion of DNA. To maintain the extrusion of the DNA loop, the condensin complex must have a domain capable of generating a force to overcome the tension outside of the loop. This study proposes that the groove-shaped HEAT repeat domain Ycg1 plays the role of a molecular motor. A DNA molecule may bind to the groove electrostatically, and the weak binding force facilitates the random thermal motion of DNA molecules. A mechanical model that random collisions between DNA and the nonparallel inner surfaces of the groove may generate a directional force which is required for the loop extrusion to sustain. The hinge domain binds to the DNA molecule and acts as an anchor during asymmetric DNA loop extrusion. When the effects of ATP hydrolysis and the viscous drag of the fluid environment are considered, the motor-anchor model for the condensin complex and the mechanical model might explain the asymmetric loop extrusion, the formation of steps, the step size distribution in the loop extrusion, the tension-dependent extrusion speed, the interaction between coexisting loops on the DNA strand, and untying the knots during extrusion. This model can also explain the observed formation of the Z-loop.

Study on printability of 3D printing carbon fiber reinforced eco-friendly concrete: Characterized by fluidity and consistency

Carbon fibers have often been added to concrete as reinforcement. Eco-friendly concrete with industrial by-products has been widely studied and applied as green building materials. Studying the workability and printability of eco-friendly concrete with carbon fibers is worthwhile. The workability and printability of eco-friendly concrete are dominating factors that ensure that printing can be carried out smoothly. This study uses a combination of experiments and numerical simulations to study the printing performance of carbon fiber-reinforced eco-friendly concrete (CFREFC). The workability and printability of 9 mixes of 3D printing CFREFC under various combinations of different water-binder (w/b) ratio levels and superplasticizer (SP) dosages were tested. Two methods, namely the consistency and fluidity tests, were used to characterize the printability. After consistency and mortar fluidity tests, the 9 mixtures were printed to get the printing performance. Finally, the relationship between the workability and printability of 3D printing CFREFC was established. The condition numbered M7 (w/b = 0.4, SP = 0.5) in the selected experimental group was used as the source of its simulation parameter. The result shows that it is feasible to characterize printability using workability, i.e., consistency and fluidity, which increase with the increase of w/b and SP dosage. Under the printing parameters of the HC1008 printer were determined, i.e., 20 mm of nozzle size, 50 mm/s of printing speed, 30 rpm of material extrusion speed, and 14 mm layer height, the fresh CFREFC was not suitable for 3DP application when its consistency is less than 48.99 mm and more than 81.96 mm, or when its fluidity is less than 166.72 mm and more than 200.93 mm. When the consistency is from 56.34 to 65.61 mm, and the fluidity is from 172.18 to 183.30 mm, the printability of CFREFC is the best under the same printing parameters. The simulation results indicated that with the increased number of printing layers, the bottom of the printed model would be deformed by the gradual increase in pressure, and a specific height loss would occur, which was consistent with the experimental results.

Regulation of dynamic recrystallization in p-type Bi2Te3-based compounds leads to high thermoelectric performance and robust mechanical properties

Bi2Te3-based bulk materials are the best commercially available thermoelectric materials for near room temperature applications. However, the poor mechanical properties of zone melting material and inferior thermoelectric performance of powder metallurgical material restrict their large scale deployment. In this study, p-type Bi₂Te₃-based materials were prepared using the hot extrusion technique, and the underlying mechanisms for microstructure evolution were revealed. The hot extrusion speed significantly impacts the strain rate, an indicator to modulate the dynamic recrystallization (DRX) and grain growth, thereby effectively regulating the microstructures of samples. For the sample extruded at a speed of 1.0 mm min−1, the refined grain with an average grain size of 1.53 μm and an orientation factor F(110) of 0.28 is achieved. This highly textured structure and high-density low-angle boundaries (LAGBs) maintain the high carrier mobility of 264 cm2 V−1 s−1, comparable with the zone melting sample. In contrast, increasing grain boundaries, dislocations, and inherent point defects intensifies the phonon scattering and suppresses the lattice thermal conductivity to 0.73 W m−1 K−1. All these contribute to a practical high ZT value of 1.1 at room temperature. Moreover, the fine grains and high-density dislocations ensure robust mechanic properties with a compressive strength of 189 MPa and a bending strength of 139 MPa, which is a guarantee for the successful cutting of microparticles with dimensions of 100 × 100 × 200 μm3. The fabrication of high-quality materials with both high thermoelectric performance and strong mechanical properties paves the way for the miniaturization of thermoelectric modules.

Feasibility of continuous switching 3D printing on surimi

Continuous switching 3D printing that allows multiple materials printed in a single nozzle was introduced to verify its applicability to the food system, which aims to improve the switching ability and manufacturing precision of multi-material 3D printed food. By integrating a self-developed 3D printing platform with logical adjustments of extrusion pressure and 3D motion, the feasible continuous switching of surimi was achieved. Moreover, employing a dual-channel continuous switching extrusion nozzle, the study elucidated the influence of surimi rheological properties on the interface behavior between pastes during extrusion. Through the analysis of fluid dynamics behavior of channel flow and utilization of simulation technology, a channel extension solution was formulated. Extending the length of the non-extrusion channel to 15 mm effectively prevented intrusion over 4 mm at an extrusion speed of 40 mm/s. This study managed to repetitively switch between two kinds of surimi pastes within a 2 mm unit length. Meanwhile, three types of 3D printing modes were established based on the control of Gcode, and the corresponding model offset correction enabled precise deposition of 2 mm × 1 mm units. The research also succeeded in 3D printing complex structures, such as meat-fat structure of beef based on surimi.

A multidisciplinary approach to investigate the influence of process parameters on interlayer adhesion in material extrusion additive manufacturing

This study investigates the influence of deposition conditions in material extrusion (MEX) on fracture toughness, with a specific focus on the interlayer adhesion. A full factorial experimental design was employed, varying three key parameters: the deposition strategy, the extrusion multiplier, and the extruder speed. Fracture toughness was assessed using double cantilever beam tests, following ASTM D5528 standards. Additionally, the study explores the influence of load direction through various deposition strategies, including 0/90 and ± 45 orientations. To gain deeper insights, real-time thermal analysis was conducted during deposition, utilizing an infrared thermal camera. This allowed to investigate the effect of deposition conditions on temperature history. Subsequent examination of fracture surfaces post-testing was performed using optical and scanning electron microscopy. The findings reveal compelling evidence of the significant impact of the extrusion multiplier, printing speed, and deposition orientation on interlayer adhesion. In addition, the results indicated the presence of crystalline phase after deposition which was due to partially melting during depositions involving high material flow. This was due to the adoption of a semicrystalline filament. The adoption of the multidisciplinary approach enabled a better understanding of some phenomena occurring during the deposition (e.g., formation/existence of crystalline phase) that influence the adhesion behavior. These results underline the capability of such broad approach to analyze the influence of the processing conditions on the interlayer adhesion. Consequently, the developed analysis procedure represents a pivotal approach to study and optimize the MEX process and filament characteristics especially for semicrystalline polymers.

Physical field regulation of magnesium alloy wheel formed by backward extrusion process with multi-stage variable speed

To reduce the tonnage required during the forming process of magnesium (Mg) alloy wheels by backward extrusion (BE) and refine the grains at the wheel bottom, the multi-stage variable (MSV) speed process is proposed based on the characteristics of Mg alloy wheels formed by BE. A numerical model for the BE process of Mg alloy wheels using the Defrom-3D was constructed, and the effects of constant speed and MSV speed processes on the physical fields and DRXed grain size evolution during the forming of Mg alloy wheels were investigated. Lastly, the simulation results were indirectly verified by industrial trial production. The results show that constant speed extrusion has a small effect on the effective stress, but a large effect on the wheel temperature distribution, where the forming speed of the upper rim plays a decisive role in the final temperature distribution of the wheel. MSV speed process is used to regulate the physical field evolution during wheel forming based on the effect of constant speed on the physical field of the wheel. With the high-speed forming of the rim and low-speed forming of the upper wheel rim (9-9-1 mm/s), the temperature and effective stress distribution of the wheel blank are reasonable while reducing the forming tonnage and refining the grains at the wheel bottom.