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Modeling of the Stainless Steel Tube Extrusion Process

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Modeling of the Stainless Steel Tube Extrusion Process ISSN: 1402-1544 ISBN 978-91-86233-XX-X Se i listan och fyll i siffror där kryssen är DOCTORAL T H E SIS Department of Applied Physics and Mechanical Engineering Division of Material Mechanics Sofia Hansson Extrusion Process Modeling Tube of the Stainless Steel ISSN: 1402-1544 ISBN 978-91-7439-064-3 Modeling of the Stainless Luleå University of Technology 2010 Steel Tube Extrusion Process Sofia Hansson Modeling of the Stainless Steel Tube Extrusion Process Sofia Hansson Luleå University of Technology Department of Applied Physics and Mechanical Engineering Division of Material Mechanics Printed by Universitetstryckeriet, Luleå 2009 ISSN: 1402-1544 ISBN 978-91-7439-064-3 Luleå 2010 www.ltu.se Abstract Seamless tubes of stainless steel can be extruded using glass as a lubricant in the Ugine-Sejournet process. The process is performed at high temperature and is associated with large deformations and high strain rates. The use of finite element modeling (FEM) in the analysis and design of extrusion and other metal forming processes is constantly increasing. Computer models that with adequate accuracy can describe the material behavior during extrusion can be very useful for product and process development. The process development in industrial extrusion today is, to a great extent, based on trial and error. This often involves full size experiments which are expensive, time consuming and interfere with the production. It would be of great value if these experiments could be performed in a computer. In this work, FE models of the stainless steel tube extrusion process were de- veloped and used. Simulations were carried out for different tube dimensions and three different materials: two austenitic stainless steels and one duplex (austenitic/ferritic) stainless steel. The models were validated by comparing the predicted values of extrusion force with measurements from production presses. A large number of input parameters are used in a FE analysis of ex- trusion. This includes boundary conditions, initial conditions and parameters that describe the mechanical and thermal properties of the material. The ac- curacy of the extrusion simulation depends, to a large extent, on the accuracy of these parameters. Experimental work, both in the form of material testing and production trials, was performed in order to give an accurate description of the input parameters in these extrusion models. A sensitivity analysis was performed for one of the models and the results showed that the initial billet temperature is the parameter that has the strongest impact on the extrusion force. In order to study the temperature evolution in the billet during man- ufacturing, the entire process chain at extrusion of stainless steel tubes was simulated using FEM. This process flow model includes sub-models of induc- tion heating, expansion and extrusion. The work includes the use of a dislocation density-based material model for the AISI type 316L stainless steel. It is expected that this physically based model can be extrapolated to a wider range of strains, strain rates and temper- atures than an empirical model, provided that the correct physical processes are described by the model and that no new phenomena occur. This is of in- terest for steel extrusion simulations since this process is carried out at higher strains and strain rates than what are normally used in mechanical laboratory tests. The developed models have given important contributions to the under- standing of different phenomena that occur during extrusion of stainless steel tubes, and can be used to analyze how different process parameters affect the extrusion process. iii List of appended papers This thesis consists of an introduction and the following appended papers: Paper I Physically based material model in finite element simulation of extrusion of stainless steel tubes S. Hansson and K. Domkin Conference proceedings of the 8th International Conference on Technology of Plasticity (ICTP), Verona, Italy, 2005 Paper II Dislocations, vacancies and solute diffusion in physical based plasticity model for AISI 316L L-E. Lindgren, K. Domkin and S. Hansson Mechanics of Materials, Vol. 40 (2008), pp. 907-919 Paper III A three-dimensional finite element simulation of stainless steel tube extrusion using a physically based material model S. Hansson Conference proceedings of the 9th ESAFORM Conference on Material Forming, Glasgow, UK, 2006 Paper IV Simulations and measurements of combined induction heating and extrusion processes S. Hansson and M. Fisk Submitted for international publication Paper V FE-simulation of combined induction heating and extrusion in manufacturing of stainless steel tubes M. Fisk and S. Hansson Conference proceedings of the 10th International Conference on Computational Plasticity (COMPLAS), Barcelona, Spain, 2009 Paper VI Sensitivity analysis of a finite element model for the simulation of stainless steel tube extrusion S. Hansson and T. Jansson Submitted for international publication v Contributions to co-authored papers Six papers are appended to this thesis. Five of these are written in collabo- ration with co-authors. The author’s contribution to each paper is given below. Paper I Modeling and simulation of the extrusion process. Collection and preparation of process data for model validation. Writing in close co-operation with the co-author. Paper II Part of experimental work. Testing and evaluation of the implemented material model. Writing the experimental part. Paper III Single author. Paper IV Modeling and simulation of the expansion and extrusion processes. Evaluation of compression tests and material modeling. Major part of experimental work. Collection and preparation of process data for model validation. Writing in close co-operation with the co-author. Paper V Modeling and simulation of the expansion and extrusion processes. Collection and preparation of process data for model validation. Writing in close co-operation with the co-author. Paper VI All work except the analyses in MODDE. All writing. vii Acknowledgements The work that is presented in this thesis has been carried out at Dalarna Uni- versity in Borl¨ange and at Sandvik Materials Technology (SMT) in Sandviken, within the framework of the National postgraduate school in metal forming. I am grateful to many people for help, both direct and indirect, in writing this thesis. I could not possibly name everyone who has contributed, but I would like to mention the following: First of all, my supervisor, Professor Lars-Erik Lindgren at Lule˚aUniversity of Technology. I would not have succeeded without his guidance and support from the initial to the final level of this project. I appreciate his deep knowledge and skills in many areas, in everything from finite element analysis to off-pist skiing. It has been a pleasure working with you! The man that I most of all wish to thank, is no longer with us. Lars Hansson, Technical Director at Jernkontoret, was the driving force behind the National postgraduate school in metal forming and has served as a manager and mentor during my time as a PhD student. I can not imagine a man more passionate and enthusiastic about steel and metal forming than Lars. Thanks to him, we students got a unique insight into this world and, above all, we had a lot of fun doing it. It was a great loss to us when he passed away, only 54 years old, in September 2009. A special thanks goes to my colleagues in the graduate school: Kristina Nord´en, Mirjana Filipovic, Linda B¨acke, Mikael Jonsson, Michael Lindgren, Ylva Granbom, Tatu R¨as¨anen, Joakim Storck and Professor G¨oran Engberg at Dalarna University. I am very grateful for their help, motivation and encour- agement. You have all been good friends to me and I will never forget all the fun we have had together on travels and conferences! I could not have accomplished this project without the support from my manager at the modeling group at SMT, Erika Hedblom. I am grateful for her proof-reading and feedback on my work, but most of all for believing in me all the way along. Many thanks go to my colleagues and room-mates at the modeling group: Erik Tyldhed, David Lundstr¨om and Tomas Jansson. The friendly and stimu- lating atmosphere at work has helped me through many times of doubt. I have really enjoyed all our discussions, on modeling, physical training and every- thing under the sun. I am especially grateful to Tomas for good co-operation on one of the papers and for help with the 3D remeshing. I have learnt a lot from working with two of SMT’s experts on the extrusion process: Bj¨orn Edstr¨om and Sune Karlsson. I would like to thank them for being so helpful and showing interest for modeling in general and in my project in particular. I would also like to thank everybody at the division of Material Mechanics at Lule˚aUniversity of Technology for making my stays in Lule˚aso pleasant. ix Special thanks to Martin Fisk for good co-operation on two of the papers. Financial support from the Swedish Steel producers’ association (Jernkon- toret), Sandvik Materials Technology and the Knowledge foundation (KK- stiftelsen) is gratefully acknowledged. Finally, I would like to thank Robert, Mum, Dad and Anders for their endless support and encouragement during the periods of hard work, and for always believing in me. Sofia Hansson G¨avle, January 2010. x Contents 1 Introduction 1 1.1 Aim and scope of the current work ................ 1 1.2 Disposition ............................. 2 2 The extrusion process 3 3 Extrusion of stainless steel tubes 5 3.1 Billet preparation .......................... 7 3.2 Stainless steel alloys for tube extrusion .............. 7 3.3 Billet heating before extrusion ................... 8 3.3.1 Induction heating ...................... 8 3.4 Glass lubrication .......................... 10 3.5 Temperature changes during extrusion .............. 12 4 Modeling and simulation of extrusion 13 4.1 Different types of finite element methods ............
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