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Energy Dissipation Characteristics Modelling for Hot Extrusion Forming of Aluminum-Alloy Components

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Abstract

The hot extrusion forming process is widely used to process aluminum-alloy components in both the automobile and aircraft manufacturing industries. Since it involves pushing the material through the die at increased temperature, it is very energy-intensive despite requiring less blank material allowance. During hot extrusion forming, the multi-stage dynamic conversion of electricity, mechanical energy, and hydraulic energy to heat results in high energy dissipation. In order to improve the power and energy conversion efficiency of hot extrusion forming process, it is necessary to identify the energy dissipation characteristics. The transfer and conversion paths of the electrical, mechanical, and hydraulic energy from the motor to the hydraulic cylinder were firstly depicted based on the motion cycle of the extruder. A bond graph-based energy dissipation model was then proposed for dynamically identifying the energy-saving potentials. The energy dissipation model integrated the power bond graph sub-model of energy conversion elements such as motor, pump, hydraulic valve group, and hydraulic cylinder. These power bond graph sub-models were separately developed to find the energy dissipation state equations of energy conversion elements. An experiment was carried out using data obtained from the energy management system to validate the bond graph-based energy dissipation model. The results have shown that the power and energy conversion efficiency of hot extrusion forming is primarily controlled by the parameters such as extrusion velocity and extrusion force. Both the higher extrusion velocity and lower extrusion force will reduce the power and energy conversion efficiency. An optimal combination of extrusion velocity and pressure can achieve the lowest energy consumption per unit product.

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Abbreviations

Rω :

The resistive effect caused by the motor rotational velocity

Rfan:

The resistive effect caused by motor shaft friction resistance

Ck :

The capacitive effect caused by motor output shaft compliance

Ix :

The inductive effect of motor rotational inertia

Tω :

The motor input torque

Tf :

The torque of overcoming resistance

T0 :

The motor output torque

Tx :

The torque of overcoming the motor rotor inertia moment

∆ωk :

The torsional deviation

ωx :

The rotational velocity of the motor when it overcomes wind resistance

ω0 :

The motor output speed

Sω :

Effort source, and it equal to excitation velocity of the motor

Se0 :

Effort source, and is equal to the motor output speed

Rfp:

The resistive effect caused by friction of pump

Rlp:

The resistive effect caused by internal leakage resistance of the pump

Ry :

The resistive effect caused by liquid resistance of pipeline

Cp :

The capacitive effect caused by liquid volume in pump oil supply line

Iy :

The inductive effect caused by the rotational inertia of the pump

Ty :

The torque to overcome the moment of inertia of rotating part of the pump

Tfp :

The torque to overcome the friction of the pump

Q1 :

The flow for overcoming internal resistance of the pump

Qp :

The input flow of the pump

Qy :

The flow to overcome the liquid resistance of the pipeline

∆Qp :

The flow rate to overcome the liquid capacity of the pipeline

Sfp:

Flow source, and is equal to the pump output flow

Sfacin:

Flow source, and is equal to the auxiliary cylinder input flow

Rcv1:

The resistive effect caused by internal fluid friction of the two way cartridge valve

Rcv2:

The resistive effect caused by internal fluid friction of the two way cartridge valve

Rkcv:

The resistive effect caused by liquid resistance of damping hole

Rfcv:

The resistive effect caused by liquid resistance of valve port

Ctcv:

The capacitive effect is caused by two-way cartridge valve spring compliance

Ifcv:

The inductive effect caused by inertia force of two-way cartridge valve core

Seincv:

Effort source and it equal to the two-way cartridge valve input speed

Seoutcv:

Effort source, and it equal to the two-way cartridge valve output speed

Rfv :

The resistive effect caused by valve port liquid resistance

Rkv :

The resistive effect caused by liquid resistance of pressure relief valve damping hole

Ctv :

The capacitive effect which is caused by pressure relief valve spring compliance

Ifv :

The inductive effect caused by inertia force of pressure relief valve core

Sev :

Effort source, and is equal to the spring speed

Sfv :

Flow source, and is equal to the pressure relief valve input flow

Sf5 :

Flow source, and is equal to the pressure relief valve output flow

Rfmc :

The resistive effect caused by friction of the main cylinder rod

Rmc:

The resistive effect caused by fluid friction of the main cylinder

Imc:

The inductive effect of main cylinder inertia

Sfmc1:

Flow source, and is equal to the main cylinder input flow

Sfmc2:

Flow source, and is equal to the main cylinder input flow

Rfac1:

The resistive effect caused by liquid resistance of the auxiliary cylinder

Rfac2:

The resistive effect caused by liquid resistance of the auxiliary cylinder

Imac1:

The inductive effect of auxiliary cylinder drive inertia

Imac2:

The inductive effect of auxiliary cylinder drive inertia

Cin:

The capacitive effect caused by auxiliary cylinder volume

Sfacout:

Flow source, and is equal to the auxiliary cylinder output flow

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (NSFC) (NO.51805066), Natural Science Foundation of Chongqing (NO. cstc2018jcyjAX0579), and Post-Doctoral Foundation of Chongqing Human Resources and Social Security Bureau.

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Authors and Affiliations

  1. School of Advanced Manufacturing Engineering, Chongqing University of Posts and Telecommunications, Chongqing, 400065, China

    Hongcheng Li, Yuanjie Wu & Feng Lu

  2. State Key Laboratory of Mechanical Transmission, Chongqing University, 174 Shazheng St., Shapingba, Chongqing, 400044, China

    Huajun Cao & Congbo Li

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  1. Hongcheng Li
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Correspondence to Huajun Cao.

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Li, H., Wu, Y., Cao, H. et al. Energy Dissipation Characteristics Modelling for Hot Extrusion Forming of Aluminum-Alloy Components. Int. J. of Precis. Eng. and Manuf.-Green Tech. 9, 1439–1461 (2022). https://doi.org/10.1007/s40684-021-00410-y

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