Skip to main content
SpringerLink
Log in

Research on extrusion forming rule of a self-bending die of distorted channel

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper introduces a new type of die, a self-bending die of distorted channels. It can directly form curved profiles from billets in a single extrusion operation. A series of experiments were undertaken with plasticine instead of AA6063 aluminum alloy as the model workpiece material. The stability of the bending arc curvature of the profile, the influence of the process parameters, and the die structure parameters on the curvature radius of the extruded profile were studied by a combination of experiment and simulation during extrusion. The results have shown that the speed distribution of the metal at the exit of the die is linear, and the curvature radius of the extruded profile is stable. The radius of curvature of the profile is affected by the extrusion speed and friction factor, and it decreases with the increase in extrusion speed and friction factor. The radius of curvature also depends on the preheating temperature of the billet, and the increase in the preheating temperature leads to the increase in the curvature radius, although the radius of curvature is less sensitive to it than to extrusion speed and friction factor. The influence of the extrusion ratio on the radius of curvature of the profile is related to the width of the inlet die hole and the width of the outlet die hole. The radius of curvature increases with the width of the inlet die hole and the width of the outlet die hole.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

Availability of data and materials

All data generated or analyzed during this study are included in this article.

Code availability

The code is available.

References

  1. Lu X, Yu J, Yardley VA, Liu H, Shi Z, Lin J (2021) Solid-state welding and microstructural features of an aluminium alloy subjected to a novel two-billet differential velocity sideways extrusion process. J Mater Process Technol 296. https://doi.org/10.1016/j.jmatprotec.2021.117189

  2. Ranjan Yadav R, Dewang Y, Raghuwanshi J, Sharma V (2020) Finite element analysis of extrusion process using aluminum alloy. Mater Today: Proc 24:500–509. https://doi.org/10.1016/j.matpr.2020.04.302

    Article  Google Scholar 

  3. Yu J, Lin J, Dean TA (2020) Development of novel differential velocity sideway extrusion techniques to fabricate lightweight curved structural components. Procedia Manuf 50:125–128. https://doi.org/10.1016/j.promfg.2020.08.023

    Article  Google Scholar 

  4. Qamar SZ, Chekotu JC, Qamar SB (2019) Effect of shape complexity on ram pressure and metal flow in aluminum extrusion. Jom 71:4378–4392. https://doi.org/10.1007/s11837-019-03748-6

    Article  Google Scholar 

  5. Whalen S, Olszta M, Reza-E-Rabby M, Roosendaal T, Wang T, Herling D, Taysom BS, Suffield S, Overman N (2021) High speed manufacturing of aluminum alloy 7075 tubing by Shear Assisted Processing and Extrusion (ShAPE). J Manuf Process 71:699–710. https://doi.org/10.1016/j.jmapro.2021.10.003

    Article  Google Scholar 

  6. Ma J, Welo T, Wan D (2021) The impact of thermo-mechanical processing routes on product quality in integrated aluminium tube bending process. J Manuf Process 67:503–512. https://doi.org/10.1016/j.jmapro.2021.05.015

    Article  Google Scholar 

  7. Zhang S, Lv G, Ma F, Wang Z, Liu Y (2022) Influence of low-frequency vibration on friction coefficient of contact interface in bend-stretch forming. Int J Lightweight Mater Manuf 5:306–314. https://doi.org/10.1016/j.ijlmm.2022.03.002

    Article  Google Scholar 

  8. Yi J, Liu Z-w, Zeng W-q (2021) Isothermal extrusion speed curve design for porthole die of hollow aluminium profile based on PID algorithm and finite element simulations. Trans Nonferr Met Soc China 31:1939–1950. https://doi.org/10.1016/s1003-6326(21)65628-5

    Article  Google Scholar 

  9. Welo T, Ma J, Blindheim J, Ha T, Ringen G (2020) Flexible 3D stretch bending of aluminium alloy profiles: an experimental and numerical study. Procedia Manuf 50:37–44. https://doi.org/10.1016/j.promfg.2020.08.008

    Article  Google Scholar 

  10. Hashemi R, Niknam SA (2020) Flexible bending of rectangular profiles: numerical and experimental investigations. J Manuf Process 56:390–399. https://doi.org/10.1016/j.jmapro.2020.04.072

    Article  Google Scholar 

  11. Ghiotti A, Simonetto E, Bruschi S, Bariani PF (2017) Springback measurement in three roll push bending process of hollow structural sections. CIRP Ann 66:289–292. https://doi.org/10.1016/j.cirp.2017.04.119

    Article  Google Scholar 

  12. Zhai R, Ding X, Yu S, Wang C (2018) Stretch bending and springback of profile in the loading method of prebending and tension. Int J Mech Sci 144:746–764. https://doi.org/10.1016/j.ijmecsci.2018.06.028

    Article  Google Scholar 

  13. Namburi KPV, Kothasiri AF, Yerubandi VSM (2020) Modeling and simulation of aluminum 1100 alloy in an extrusion process. Mater Today: Proc 23:518–522. https://doi.org/10.1016/j.matpr.2019.05.398

    Article  Google Scholar 

  14. Marín MM, Camacho AM, Pérez JA (2017) Influence of the temperature on AA6061 aluminum alloy in a hot extrusion process. Procedia Manuf 13:327–334

    Article  Google Scholar 

  15. Zhou W, Lin J, Dean TA, Wang L (2017) A novel application of sideways extrusion to produce curved aluminium profiles: feasibility study. Procedia Eng 207:2304–2309. https://doi.org/10.1016/j.proeng.2017.10.999

    Article  Google Scholar 

  16. Zhou W, Lin J, Dean TA, Wang L (2018) Feasibility studies of a novel extrusion process for curved profiles: experimentation and modelling. Int J Mach Tools Manuf 126:27–43. https://doi.org/10.1016/j.ijmachtools.2017.12.001

    Article  Google Scholar 

  17. Shiraishi M, Nikawa M, Goto Y (2003) An investigation of the curvature of bars and tubes extruded through inclined dies. Int J Mach Tools Manuf 43:1571–1578. https://doi.org/10.1016/s0890-6955(03)00201-3

    Article  Google Scholar 

  18. Kaya C, Blackburn S (2004) Extrusion of ceramic tubes with complex structures of non-uniform curvatures made from nano-powders. J Eur Ceram Soc 24:3663–3670. https://doi.org/10.1016/j.jeurceramsoc.2003.12.012

    Article  Google Scholar 

  19. Wang YP, Li F, Li XW (2020) Effect of extrusion ratio (λ) on dynamic recrystallization of AZ31 magnesium alloy bending products prepared by staggered extrusion (SE). Int J Adv Manuf Technol 108:289–297. https://doi.org/10.1007/s00170-020-05416-5

    Article  Google Scholar 

  20. Min F, Liu H, Zhu G, Chang Z, Gao X, Yue B, Guo N, Zhai X (2021) Self-bending extrusion molding of distorted channels. J Mech Sci Technol 35:1945–1953. https://doi.org/10.1007/s12206-021-0412-8

    Article  Google Scholar 

  21. Assempour A, Hassannejadasl A (2009) Minimization of the exit profile curvature in non-symmetric T-shaped sections in the extrusion process. Mater Des 30:1350–1355. https://doi.org/10.1016/j.matdes.2008.06.038

    Article  Google Scholar 

  22. Min F, Liu H, Zhu G, Chang Z, Guo N, Song J (2021) The streamlined design of self-bending extrusion die. Int J Adv Manuf Technol 116:363–373. https://doi.org/10.1007/s00170-021-06760-w

    Article  Google Scholar 

  23. Kim H-Y, Kim J-J, Kim N (1994) Physical and numerical modeling of hot closed-die forging to reduce forging load and die wear. J Mater Process Technol 42:401–420. https://doi.org/10.1016/0924-0136(94)90146-5

    Article  Google Scholar 

  24. Yu J, Zhao G, Chen L (2016) Analysis of longitudinal weld seam defects and investigation of solid-state bonding criteria in porthole die extrusion process of aluminum alloy profiles. J Mater Process Technol 237:31–47. https://doi.org/10.1016/j.jmatprotec.2016.05.024

    Article  Google Scholar 

  25. Yi J, Wang Z-h, Liu Z-w, Zhang J-m, He X (2018) FE analysis of extrusion defect and optimization of metal flow in porthole die for complex hollow aluminium profile. Trans Nonferr Met Soc China 28:2094–2101. https://doi.org/10.1016/s1003-6326(18)64853-8

    Article  Google Scholar 

  26. Irani M, Joun M (2018) A study of plastic deformation behavior of AA1050 aluminum alloy during pure shear extrusion with back pressure. Russian J Non-Ferrous Met 58:632–638. https://doi.org/10.3103/s1067821217060049

    Article  Google Scholar 

  27. Min F, Zhu G, Yue B, Wang Z, Yang Z, Zhai X (2020) Influence of exit velocity distribution on self-bending extrusion. Eng Res Express 2. https://doi.org/10.1088/2631-8695/ab7154

Download references

Funding

This work was supported by the Natural Science Foundation of Shandong Province (Project Number ZR2017MEE036) and Zibo City School City Integration Development Project (Project Number 2017ZBXC205).

Author information

Author notes

  1. Zheng Chang and Guangming Zhu contribute equally to this work, they are all corresponding authors.

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University of Technology, 266 Xincun West Road, Zibo, 255000, People’s Republic of China

    Jianbo Song, Yuanhao Wang, Bowen Yue, Xujie Gao, Nana Guo, Lihua Zhu & Guangming Zhu

  2. School of Computer Science and Technology, Shandong University of Technology, 266 Xincun West Road, Zibo, 255000, People’s Republic of China

    Zheng Chang

Authors
  1. Jianbo Song
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuanhao Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Bowen Yue
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xujie Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Nana Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Lihua Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Zheng Chang
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Guangming Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Jianbo Song: software, validation, writing—original draft, and writing—review and editing. Bowen Yue: software, validation, and writing—original draft. Guangming Zhu: resources and supervision. Zheng Chang: resources and supervision. Yuanhao Wang, Nana Guo, Xujie Gao, and Lihua Zhu: investigation. All authors read and approved the final manuscript.

Corresponding authors

Correspondence to Zheng Chang or Guangming Zhu.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Song, J., Wang, Y., Yue, B. et al. Research on extrusion forming rule of a self-bending die of distorted channel. Int J Adv Manuf Technol 124, 2351–2363 (2023). https://doi.org/10.1007/s00170-022-10482-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10482-y

Keywords

Search

Navigation