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Backward Can Extrusion and Materials Behaviour

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Backward Can Extrusion and Materials Behaviour Backward can extrusion and materials behaviour Citation for published version (APA): Sillekens, W. H. (1992). Backward can extrusion and materials behaviour. Technische Universiteit Eindhoven. https://doi.org/10.6100/IR374925 DOI: 10.6100/IR374925 Document status and date: Published: 01/01/1992 Document Version: Publisher’s PDF, also known as Version of Record (includes final page, issue and volume numbers) Please check the document version of this publication: • A submitted manuscript is the version of the article upon submission and before peer-review. There can be important differences between the submitted version and the official published version of record. People interested in the research are advised to contact the author for the final version of the publication, or visit the DOI to the publisher's website. • The final author version and the galley proof are versions of the publication after peer review. • The final published version features the final layout of the paper including the volume, issue and page numbers. Link to publication General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. • Users may download and print one copy of any publication from the public portal for the purpose of private study or research. • You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal. If the publication is distributed under the terms of Article 25fa of the Dutch Copyright Act, indicated by the “Taverne” license above, please follow below link for the End User Agreement: www.tue.nl/taverne Take down policy If you believe that this document breaches copyright please contact us at: [email protected] providing details and we will investigate your claim. Download date: 27. Sep. 2021 Backward Can Extrusion and Materials Behaviour W. H. Sillekens CJP-GEGEVENS KONINKLIJKE BIBLIOTHEEK, DEN HAAG Sillekens, Wilhelmus Hubertina Backward can extrusion and materials behaviour 1 Wilhelmus Hubertina Sillekens. - Eindhoven : Technische Universiteit Eindhoven. - 111. Proefschrift Eindhoven. - Met lit. opg. - Met samenvatting in het Nederlands. ISBN 90-386-0032·1 Trefw.: omvormtechniek. Druk: drukkerij Creemers, Sint Odiliënberg Dit proefschrift is goedgekeurd door de promotoren: prof. ir. J.A.G. Kals en Prof. Dr.-Ing. R. Kopp copromotor: dr. ir. J.H. Dautzenberg Backward Can Extrusion and Materials Behaviour PROEFSCHRIFT ter verkrijging van de graad van doctor aan de Technische Universiteit Eindhoven, op gezag van de Rector Magnificus, prof. dr.• I.H. van Lint, voor een commissie aangewezen door het College van Dekanen in het openbaar te verdedigen op vrijdag 5 juni 1992 om 14.00 uur door WILHELMUS HUBERTINA SILLEKENS geboren te Herten vii Summary This thesis reports on a studyin the field of metal forming. Topic is the bulk-forming process of backward can extrusion in relation to the plastic behaviour of the worked material. The issue of the workpiece material's behaviour during forming is an interesting one: it is here where the fields of materials science and forming technology have a common relevance. A better insight into these phenomena - tor the aim of better process control - requires the inlegration of aspects trom both disciplines. lt is in this context that the present contribution must be regarded. Backward can extrusion is used in the mass production of discrete parts tor the manufacture of can-shaped components. lndustrial productions cover a variety of shapes, sizes and materials; these products are utilised in a diversity of consumer goods. Presently available methods of backward can extrusion modelling are reviewed. These are classified in experimental, analytica!, and numerical methods. Special emphasis is placed on the category of analytica! models. Same important upper-bound models, proposed in the literature, are introduced. A comparison on the basis of the upper-bound principle makes clear that each of the treated models has an outlined validity range. From a combination of these models, it is possible to calculate the ram pressure as a tunetion of the ram stroke tor the initia! and the final stage of the process. In addition, information is acquired concerning the material flow. A further account deals with the properties, which are important in the evaluation of a (new) material tor forming applications. A number of characteristic quantities is discussed; these reprasent distinct features of the tormability, like flow behaviour, failure behaviour, and plastic anisotropy. These quantities, as they are obtained trom basic material tests, can be used to formulate some directives for the application. Aluminiuïn, redaimed trom scrap by rapid-solidification processing, is used as an illustrative material. viii Summary Next, the attention concentratas on a particular aspect of the workpiece material's properties: the flow behaviour. This flow behaviour can be represented by means of a flow curve, which depiets the flow stress as a tunetion of the plastic strain. Except tor the influence of strain rate and temperature, such a flow curve does depend also on the strain path; this is of importance since different processes, in genera!, entail different strain paths. The strain-path dependenee of flow curves is studied. Corresponding results of compression, torsion and tension tests are compared to each ether and to those trom tests, invalving an abrupt change in the deformation mode. Obtained flow curves are described by means of an accommodated flow function. Concerning the backgrounds to these phenomena, possible crigins are discussed. In condusion, the behaviour of the workpiece material is interpreled with respect to the backward can extrusion process. An application concerns the modelling of the process trom a viewpoint of the workpiece material's ductility. An analytica! model tor the calculation of local strains and stresses is introduced. Finite-element simuiatien serves as a verification. The failure behaviour is determined experimentally, and is represented by means of ductile-failure curves. From a confrontation of the analytica! results with this experimental information, as well as with actual extrusion experiments, an insight is gained into the process limit of material tracture. ix Samenvatting Dit proefschrift beschrijft de resultaten van een studie op het gebied van de omvorm­ techniek. Onderwerp is het massief-omvormproces achterwaartse hulsextrusie in relatie tot het bewerkingsgedrag van het werkstukmateriaaL Het gedrag van het werkstukmateriaal is van bijzondere interesse: de kennisgebieden van materiaalkunde en omvormtechnologie hebben hier een raakvlak. Inzicht in dit gedrag is van belang voor een betere procesbeheersing. Dit vereist een integratie van kenniselementen uit beide disciplines; in deze context moet het gepresenteerde onderzoek worden geplaatst. Achterwaartse hulsextrusie (of slagextrusie) wordt toegepast in de massa­ fabricage van busvormige metalen onderdelen. Industriële produkties omvatten een scala aan vormen, afmetingen en materialen; deze produkten vinden toepassing in een verscheidenheid aan gebruiksgoederen. Beschikbare methoden van procesmodellering worden besproken. Deze zijn ingedeeld naar de manier van aanpak in experimentele, analytische en numerieke methoden. De belangstelling gaat vooral uit naar de klasse van bovengrensmodellen; hiervan is een inventarisatie gemaakt- gebaseerd op de literatuur. Toepassing van het bovengrensprincipe maakt duidelijk welk model het beste voldoet voor de verschillende procescondities; elk van de modellen blijkt een eigen geldigheidsgebied te hebben. Door combinatie van deze modellen wordt zowel het begin- als het eindstadium van het proces analytisch beschreven, waarbij het verloop van de stempeldruk wordt voorspeld. Bovendien wordt een indicatie verkregen betreffende de materiaalstroom. Verdere aandacht gaat uit naar de materiaaleigenschappen, die van belang zijn bij de beoordeling van een (nieuw) materiaal voor omvormende bewerkingen. Een aantal karakteristieke grootheden wordt hierbij gehanteerd, die onderscheiden kenmerken van de omvormbaarheid kwantificeren. Hierin zijn begrepen: het vloeigedrag, de ductiliteit (deformatievermogen), de plastische anisotropie. Deze grootheden zijn met behulp van materiaalproeven bepaald. Aan de hand hiervan kunnen richtlijnen worden geformuleerd voor de bewerking. Als illustratief materiaal is x Samenvatting gerecycled aluminium gebruikt, verkregen uit het basismateriaal via een snelle stollingstechniek. Eén belangrijk aspect van het materiaalgedrag betreft het llloeigedrag. Dit vloeigedrag kan worden weergegeven met behulp van een vloeikromme, die de vloeispanning van het materiaal vastlegt als functie van de plastische rek. Behalve van reksnelheid en temperatuur blijkt de vloeikromme ook afhankelijk te zijn van de rekweg; dit is van belang omdat deze rekweg varieert per omvormproces. De rekweg­ afhankelijkheid is experimenteel onderzocht, enerzijds aan de hand van stuik-, torsie­ en trekproeven, anderzijds door gecombineerde proeven met abrupte overgangen in de rekweg. Een aangepaste vloeifunctie is gebruikt om het gedrag te kwantificeren. Mogelijke oorzaken van verschillen in vloeigedrag worden behandeld. Tot slot wordt het gedrag van het werkstukmateriaal
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