Skip to main content
SpringerLink
Log in

Analysis and porthole die design for a multi-hole extrusion process of a hollow, thin-walled aluminum profile

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

Abstract

The appropriate die design for multi-hole extrusion is still a challenging task because of the complicated circumstances and large material deformation during extrusion process. In the present study, the material flow during multi-hole extrusion process for producing a hollow and thin-walled profile was revealed by means of numerical simulation based on the Arbitrary Lagrangian Eulerian (ALE) method. The effects of eccentricity ratio, shape of the second-step welding chamber, and uneven bearing length on the exit velocity distribution of extrudate were synthetically investigated, and a two-hole porthole die was designed accordingly. The exit velocity and temperature on the extrudate in this optimized die were analyzed and compared with the initial die, and it was found that both of them exhibit better uniformity, which is beneficial for the enhancement of product quality. Through performing the current work, a logical and effective route for designing multi-hole porthole die was proposed as the guidance for die designers.

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

Similar content being viewed by others

References

  1. Liu G, Zhou J, Duszczyk J (2008) FE analysis of metal flow and weld seam formation in a porthole die during the extrusion of a magnesium alloy into a square tube and the effect of ram speed on weld strength. J Mater Process Technol 200:185–198

    Article  Google Scholar 

  2. Sinha MK, Deb S, Das R, Dixit US (2009) Theoretical and experimental investigations on multi-hole extrusion process. Mater Des 30:2386–2392

    Article  Google Scholar 

  3. Liu P, Xie S, Cheng L (2012) Die structure optimization for a large, multi-cavity aluminum profile using numerical simulation and experiments. Mater Des 36:152–160

    Article  Google Scholar 

  4. Farjad Bastani A, Aukrust T, Brandal S (2011) Optimisation of flow balance and isothermal extrusion of aluminium using finite-element simulations. J Mater Process Technol 4:650–667

    Article  Google Scholar 

  5. Duan X, Sheppard T (2003) Simulation and control of microstructure evolution during hot extrusion of hard aluminium alloys. Mater Sci Eng A 351:282–292

    Article  Google Scholar 

  6. Wu X, Zhao G, Luan Y, Ma X (2006) Numerical simulation and die structure optimization of an aluminum rectangular hollow pipe extrusion process. Mater Sci Eng A 435:266–274

    Article  Google Scholar 

  7. Wu CY, Hsu YC (2002) Optimal shape design of an extrusion die using polynomial networks and genetic algorithms. Int J Adv Manuf Technol 19:79–87

    Article  Google Scholar 

  8. Zhou J, Li L, Duszczyk J (2004) Computer simulated and experimentally verified isothermal extrusion of 7075 aluminium through continuous ram speed variation. J Mater Process Technol 146:203–212

    Article  Google Scholar 

  9. Duan X, Velay X, Sheppard T (2004) Application of finite element method in the hot extrusion of aluminium alloys. Mater Sci Eng A 369:66–75

    Article  Google Scholar 

  10. Lof J, Blokhuis Y (2002) FEM simulations of the extrusions of complexed thin-walled aluminum sections. J Mater Process Technol 122:344–354

    Article  Google Scholar 

  11. Jo HH, Lee SK, Jung CS, Kim BM (2006) A non-steady state FE analysis of Al tubes hot extrusion by a porthole die. J Mater Process Technol 173:223–231

    Article  Google Scholar 

  12. Fang G, Zhou J, Duszczyk J (2009) Extrusion of 7075 aluminium alloy through double-pocket dies to manufacture a complex profile. J Mater Process Technol 209:3050–3059

    Article  Google Scholar 

  13. Fang G, Zhou J, Duszczyk J (2008) Effect of pocket design on metal flow through single-bearing extrusion dies to produce a thin-walled aluminium profile. J Mater Process Technol 199:91–101

    Article  Google Scholar 

  14. Kathirgamanathan P, Neitzert T (2009) Optimization of pocket design to produce a thin shape complex profile. Prod Eng Res Dev 3:231–241

    Article  Google Scholar 

  15. Chen H, Zhao G, Zhang C, Guan Y, Liu H, Kou F (2011) Numerical simulation of extrusion process and die structure optimization for a complex aluminum multicavity wallboard of high-speed train. Mater Manuf Process 26:1530–1538

    Article  Google Scholar 

  16. Li F, Lin JF, Yuan J, Liu XJ (2009) Effect of inner cone punch on metal flow in extrusion process. Int J Adv Manuf Technol 42:489–496

    Article  Google Scholar 

  17. Zhang CS, Zhao GQ, Chen H, Guan YJ, Kou FJ (2012) Numerical simulation and metal flow analysis of hot extrusion process for a complex hollow aluminum profile. Int J Adv Manuf Technol 60:101–110

    Article  Google Scholar 

  18. Sun X, Zhao G, Zhang C, Guan Y, Gao A (2013) Optimal design of second-step welding chamber for a condenser tube extrusion die based on the response surface method and the genetic algorithm. Mater Manuf Process 28:823–834

    Article  Google Scholar 

  19. Peng Z, Sheppard T (2004) Simulation of multi-hole die extrusion. Mater Sci Eng A 367:329–342

    Article  Google Scholar 

  20. He YF, Xie SS, Cheng L, Huang GJ, Fu Y (2010) FEM simulation of aluminum extrusion process in porthole die with pockets. Trans Nonferrous Met Soc China 20:1067–1071

    Article  Google Scholar 

  21. Ulysse P, Johnson RE (1998) A study of the effect of the process variables in unsymmetrical single-hole and multi-hole extrusion processes. J Mater Process Technol 73:213–225

    Article  Google Scholar 

  22. Guan Y, Zhang C, Zhao G, Sun X, Li P (2012) Design of a multihole porthole die for aluminum tube extrusion. Mater Manuf Process 27:147–153

    Article  Google Scholar 

  23. Zhang C, Zhao G, Chen H, Guan Y, Cai H, Gao B (2012) Investigation on effects of die orifice lon three-hole porthole extrusion of Aluminum Alloy 6063 tubes. J Mater Eng Perform 22:1223–1232

    Article  Google Scholar 

  24. Sinha MK, Deb S, Dixit US (2009) Design of a multi-hole extrusion process. Mater Des 30:330–334

    Article  Google Scholar 

  25. Qamar SZ, Arif AFM, Sheikh AK (2004) A new definition of shape complexity for metal extrusion. J Mater Process Technol 155:1734–1739

    Article  Google Scholar 

  26. Ganvir V, Lele A, Thaokar R, Gauthama BP (2009) Prediction of extrudate swell in polymer melt extrusion using an Arbitrary Lagrangian Eulerian (ALE) based finite element method. J Non-Newtonian Fluid Mech 156:21–28

    Article  MATH  Google Scholar 

  27. Aymone JLF, Bittencourt E, Creus GJ (2001) Simulation of 3D metal-forming using an arbitrary Lagrangian-Eulerian finite element method. J Mater Process Technol 110:218–232

    Article  Google Scholar 

  28. Zhang C, Zhao G, Chen H, Guan Y, Li H (2012) Optimization of an aluminum profile extrusion process based on Taguchi’s method with S/N analysis. Int J Adv Manuf Technol 60:589–599

    Article  Google Scholar 

  29. Ma X, de Rooij MB, Schipper DJ (2012) Friction conditions in the bearing area of an aluminium extrusion process. Wear 278:1–8

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, Shandong, 250061, People’s Republic of China

    Liang Chen, Guoqun Zhao, Junquan Yu, Wendong Zhang & Tao Wu

Authors
  1. Liang Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guoqun Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Junquan Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Wendong Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Tao Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Liang Chen or Guoqun Zhao.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chen, L., Zhao, G., Yu, J. et al. Analysis and porthole die design for a multi-hole extrusion process of a hollow, thin-walled aluminum profile. Int J Adv Manuf Technol 74, 383–392 (2014). https://doi.org/10.1007/s00170-014-6003-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-6003-4

Keywords

Search

Navigation