FLOW ANALYSIS INSIDE SHEAR AND STREAMLINED EXTRUSION DIES FOR FEEDER PLATE DESIGN A Thesis Presented to The Faculty ofthe Fritz J. and Dolores H. Russ College ofEngineering and Technology Ohio University In Partial Fulfillment Ofthe Requirement for the Degree Master ofScience By Ibrahim A. AI-Zkeri November, 1999 OHIO U HSiTY II r~1A~ y ACKNOWLEDGMENTS I would like to express my sincere appreciation to my advisor, Dr. Bhavin V. Mehta, for his valuable advice and for providing me with the information and the facilities required for this thesis. I would also like to thank Mr. Arjaan Bijk from MacNeal-Schwendler Corporation for his tremendous support during this research. Last but not least, I would like to thank my parents for their unlimited and continuous care and reassurance, my wife for her endless patience and support, and all my brothers and sisters for their encouragement. Ibrahim A. AI-Zkeri November 1999 11 TABLE OF CONTENTS LIST OF TABLES iv LIST OF FIGURES v Chapter I- INTRODUCTION......................•............................................................... 1 1.1 Extrusion History 1 1.2 Extrusion Process 4 1.3 Extrusion Die Design 9 1.4 Objective ofthe Thesis 10 Chapter II - LITERATURE REVIEW 12 Chapter III - ANALYSIS METHODOLOGy 15 3.1 Isothenn.al Extrusion 15 3.2 Steady-State Process 15 3.3 Finite-Element Method 16 3.4 Finite Volume Method 17 Chapter IV - MODELING OF EXTRUSION DIES 18 4.1 Introduction 18 4.2 STREAM 18 4.3 MSCIPATRAN 24 III Chapter V- SIMULATIONS AND ANALYSIS 30 5.1 Introduction 30 5.2 Common Preprocessing Settings 30 5.3 Simulation Using DEFORMTM-3D 33 5.4 Simulation Using MSC/SuperForge 36 Chapter VI - RESULTS......................•.•...•..........•.•...•.•...........................•................... 38 6.1 Extrusion Using Streamlined Die 38 6.1.1 DEFORMTM-3D Simulation Results 38 6.1.2 MSC/SuperForge Simulation Results 41 6.2 Extrusion Using Shear Dies 43 Chapter VII - CONCLUSION AN"D DISCUSSION 51 7.1 Conclusion 51 7.2 Discussion 52 7.3 Future Work 53 REFERENCES ........•..............•.•.......••.....•...•............•.•.•.•..••.•....................................... 54 APPENDICES..................................•.•.•.•...•....•.•.•.•.•.•••........•...•......•.•.•...•.•.•............•.... 59 Appendix A: STREAM RUN 59 Appendix B: DIE1.DAT (The Input Data File) 65 IV LIST OF TABLES Table 1: The Input Data for Streamlined Die Profile Design 23 Table 2: The Z-Level Values ofthe Selected B-Spline Curves 27 Table 3: Material Properties for Aluminum Alloy (6061-0) 31 Table 4: DEFORMTM-3D Simulation Control Settings 35 - Table 5: The Maximum Values of Press Load, c , and € for all dies 49 Table 6: Comparison ofSimulations' Results 51 v LIST OF FIGURES Figure 1: Bramah's lead-pipe machine 2 Figure 2: Horizontal extrusion press designed by Alexander Dick in 1894 3 Figure 3: Direct and indirect extrusion, with internal shearing 5 Figure 4: Various types of shear dies 7 Figure 5: Feeder plate die; the produced shape is larger than the billet size 8 Figure 6: The product cross-section shape and its dimensions 18 Figure 7: Limitations of previous methods of streamlined die design 20 Figure 8: The new concept of die design used in STREAM 21 Figure 9: Stocke's Theorem applied to die design 22 Figure 10: The mapping of the billet to the product shape 24 Figure 11: Die geometry for the streamlined die 25 Figure 12: Die geometry for the solid-shape and feeder plate dies 26 Figure 13: The billet geometry with different types of mesh 28 Figure 14: The a - £ curve of Aluminum 6061-0 32 Figure 15: Effective stress distribution when streamlined die is used (ksi) 39 Figure 16: Effective strain distribution when streamlined die is used (in/in) 40 Figure 17: The load-stroke curve of the extrusion press 40 Figure 18: Effective stress distribution when streamlined die is used (psi) 41 Figure 19: Effective strain distribution when streamlined die is used (in/in) 42 Figure 20: The load (Ibfj-stroke (in) curve of the extrusion press 43 VI Figure 21: Effective stress distribution when shape die is used (psi) 44 Figure 22: Effective strain distribution when shape die is used (in/in) 45 Figure 23: The ram load (lbf)-stroke (in) curve when shape die is used 46 Figure 24: Z-Velocity distribution when feeder plate die is used (Z=2.0) 47 Figure 25: Effective stress distribution when feeder plate die is used (Z=2.0) 47 Figure 26: Effective strain distribution when feeder plate die is used (Z=2.0) 48 Figure 27: Load (lbf)-Stroke curve ofthe ram when feeder plate die is used (Z=2.0). 48 Figure 28: Maximum effective stress for all dies used in this study 49 Figure 29: Maximum effective strain for all dies used in this study 50 Figure 30: Maximum ram load for all dies used in this study 50 Chapter I IN·TRODUCTION Today, with more advanced technology, extrusion process is used in a wide variety of applications--helicopter blades, turbine blades, wing spars, construction material, etc. Extrusion process offers significant advantages over metal working operations, especially where considerable length of the same cross-section is desired [1]. Extrusion process development revolution began more than 200 years ago with the invention of the first simple lead press and developed into the modem automatic extrusion process. The most important chapter of the extrusion process development revolution began some decades ago using computers to design extrusion dies. Today, extrusion die design is relatively easier and cheaper using the most advanced Computer-Aided Design (CAD) technology. The designer can design and modify the extrusion dies even for complex shear products without wasting any material and do.so in a relatively shorter time. 1.1 Extrusion History Extrusion has an industrial history stretching back around 200 years. It is probable that the earliest perception of the principles of extrusion was due to a famous hydraulic engineer, Joseph Bramah. He, in a patent granted in 1797, described a press (see Figure 1), "for making pipes of lead or other soft metals of all dimensions and any given length without joints" [11]. Lead, maintained molten in an iron pot (a), by a fire beneath, was forced by a pump (b) into a long projecting tube (c), which served as a die. A tapered mandrel (d) was supported concentrically with the tube by means of a bridge in its enlarged end. The lead passing through the annular space between the tube and mandrel 2 was kept molten by the fuel gases inside the outer casing until it approached the outlet, where it was chilled to cause it to solidify so that it emerged in the form of a pipe [11]. The basic principle ofBramah's press is still used today in the manufacture of lead tubes [2]. Figure 1: Bramah's lead-pipe machine [11]. There was no immediate development of Bramah's idea, and the earlier methods of making lead pipes continued to be used until 1820, when Thomas Burr, a Shrewsbury plumber, constructed a press operated by hydraulic power [11]. The development of metal extrusion processing continued. However, the inventions were limited to the extrusion oflead until 1894, when Alexander Dick got his first patent for an extrusion press that allowed non-ferrous alloys to be extruded for the first time (see Figure 2). He built a horizontal extrusion press for the Delta Metal Company in Dusseldorf, England [11,2]. Upon Dick's inventions, which he continued to improve up to the time ofhis death in 1903, the modern process ofextrusion has been founded [11]. 3 Figure 2: Horizontal extrusion press designed by Alexander Dick in 1894 [11]. Since Dick's death and until the end of the 1960's, the extrusion process has developed technically and some materials, such as steel and unusual metals including titanium, beryllium, and uranium, were added to the extruded metals. Beginning in the early 1950's, many researchers were concerned about studying the extrusion process and modeling the metal flow during the extrusion process mathematically. At the end of the 1960's, many theories that describe the extrusion process and some tips on designing the extrusion dies were available to the extrusion industry. Moreover, many researchers began thinking about modeling some new die shears in order to reduce the stresses on the extruded metal and make the metal flow as uniformly as possible. During the early 1970's, computers were used to an increasing extent for metal forming applications. For the solution of metal forming problems, two approaches can generally be employed. The first is the usual elastic-plastic approach where the material is treated as elastic-plastic. A good example ofa computer software package utilizing this approach is NlKE2D developed by John Hallquist at the Lawrence Livermore Labs., 4 USA [4]. The second is the rigid-plastic finite-element method developed by Lee and Kobayashi, which permitted large increments of deformation, therefore reducing computation time. One of the earlier software that worked on Lee and Kobayashi's approach is ALPID (Analysis of Large Plastic Incremental Deformation). ALPID was developed by S. Oh and co-workers at the Battelle Memorial Institute with U.S. Air Force Sponsorship [4,6]. 1.2 Extrusion Process Extrusion is a comparatively process among the industrial methods by which metals are wrought into useful forms, but it has succeeded in establishing itself firmly as one of the foremost of these. Essentially the process is one by which a block of solid metal (billet) is converted into a continuous length of a uniform cross-section by forcing it to flow, under high pressure, through a die orifice which is so sheard as to impart the required form to the product [11]. Extrusion is mostly carried out under high temperatures. This is dictated by the necessity of lowering the toughness ofthe metal in the pressed state in order to avoid the necessity of applying very large operating stresses.