Russian Journal of Non-Ferrous Metals

, Volume 59, Issue 6, pp 632–636 | Cite as

Simulation of the Final Stage of the Direct Extrusion Method of Large-Size Rods at Small Elongations

  • V. R. KarginEmail author
  • A. Yu. DeryabinEmail author


A simulation of the direct extrusion method of large-size rods with diameters of 188, 214, 252, 283, 326, and 560 mm made of alloy 7075; coefficients of friction of 0 and 0.5; and die cone angles of 80° and 90° from a container with a diameter of 800 mm using a 200-MN press with the help of the DEFORM-2D software package is performed. The distribution of radial velocities of metal flow on a working surface of a pressure pad depending on the contact friction, die cone angle, and elongation ratio at the main and final stages of extrusion is found. The butt-end height at the beginning instant of funnel formation is accepted equal to the distance between the pressure pad plane and input plane of extruded metal into a screw channel of flat or cone dies. The combined effect of the elongation ratio, coefficient of friction, and die cone angle on the butt-end height, extrusion force, intensities of strain rates and stresses, and temperature on the die orifice edge is investigated. Numerical experiments are performed according to the complete factorial plan 23 for variability intervals of parameters: Х1 = 3–9, Х2 = 0–0.5, Х3 = 80°–90°. Friction between the tool and the billet at the final stage of extrusion plays a negative role, noticeably decreasing the radial velocity. This leads to the earlier onset of the formation of the central funnel. Extrusion into a conical die and an increase in the elongation ratio, on the contrary, increase the radial flow velocity and provide the later onset of formation of a central funnel. The main factor that determines the butt-end height is the elongation ratio. A mathematical model is proposed to select the butt-end thickness for concrete extrusion conditions of large-dimensioned rods with small elongation ratios.


extrusion large-size bars hardly deformable aluminum alloy 7075 funnel butt end simulation experimental design matrix DEFORM program 



  1. 1.
    Lukashenko, V.N., Justification of the expediency of pressing with drawing coefficient λ < 10, Tekhnol. Llegk. Splav., 1980, no. 5, pp. 11–14.Google Scholar
  2. 2.
    Kargin, V.R. and Deryabin, A.Y., Characteristics of large bars extruding using small extrusion ratio, Key Eng. Mater., 2016, vol. 644, pp. 211–217.Google Scholar
  3. 3.
    Perlin, I.L. and Raitbarg, L.Kh., Teoriya pressovaniya metallov (Theory of Metal Pressing), Moscow: Metallurgiya, 1975.Google Scholar
  4. 4.
    Bauser, M., Sauer, G., and Siegert, K., Extrusion, USA: ASM International, 2006, 2nd ed.Google Scholar
  5. 5.
    Pradip K. Saha, Aluminum Extrusion Technology, USA: ASM International, 2000.Google Scholar
  6. 6.
    Wojciech Z. Misiolek and Richard M. Kelly, Extrusion of aluminum alloys. URL: bitstream/handle/11115/164/Extrusion%20of%20Al%20 Alloys.pdf?sequence=3 (accessed February 15, 2018).Google Scholar
  7. 7.
    Pearson, C.E., The extrusion of metals, London: Metal Industry,1960.Google Scholar
  8. 8.
    Sheppard, T., Extrusion of Aluminum Alloys, Dordrecht, Boston, London: Kliwer, 1999.CrossRefGoogle Scholar
  9. 9.
    Zinov’ev, A.V., Kolpashnikov, A.I., Polukhin, P.I., and Glebov, Yu.P., Tekhnologiya obrabotki davleniem tsvetnykh metallov i splavov (Technology of Pressure Treatment of Nonferrous Metals and Alloys), Moscow: Metallurgiya, 1992.Google Scholar
  10. 10.
    Loginov, Yu.N., Pressovanie kak metod intensivnoi deformatsii metallov i splavov (Pressing as a Method of Intensive Deformation of Metals and Alloys), Ekaterinburg: Ural. Federal. Univ., 2016.Google Scholar
  11. 11.
    Galatskaya, I.K., Metallografiya metallurgicheskikh defektov v pressovannykh polufabrikatakh iz alyuminievykh splavov (Metallography of Metallurgical Defects in Pressed Semifinished Products of Aluminum Alloys), Kuibyshev: Kuibyshev. Knizh. Izd., 1973.Google Scholar
  12. 12.
    Riyadi Tri Widodo Besar and Siswanto Waluyo Adi, The use Abaqus for teaching the development of cavity defects in forward extrusion processes, Int. J. Mech. Eng. Edikat., 2008, vol. 36, no. 3, pp. 221–224.Google Scholar
  13. 13.
    Grabarnik, L.M. and Nagaitsev, A.A., Pressovanie tsvetnykh metallov i splavov (Pressing of Nonferrous Metals and Alloys), Moscow: Metallurgiya, 1991.Google Scholar
  14. 14.
    Shcherba, V.N. and Raitbarg, L.Kh., Tekhnologiya pressovaniya metallov (Technology of Metal Pressing), Moscow: Metallurgiya, 1995.Google Scholar
  15. 15.
    Loginov Yu.N., Ershov A.A. Modeling in the QFORM software complex the formation of press sagging during pressing, Kuzn.-Shtamp. Proizvod. Obrab. Met. Davl., 2013, no. 7, pp. 42–46.Google Scholar
  16. 16.
    Belyaev, A.P., Zaitsev, A.P., Lositskii, A.F., Nozdrin, I.V., Ogurtsov, A.N., and Savel’ev, V.N., RF Patent 2151013, 2000.Google Scholar
  17. 17.
    Kargin, V.R. and Egorov, I.A., RF Patent 2492013, 2013.Google Scholar
  18. 18.
    Biswas Amit Kumar and Leventer Robert, US Patent 3919873, 1975.Google Scholar
  19. 19.
    Loginov, Yu.N., RF Patent 230699, 2007.Google Scholar
  20. 20.
    Parvizian, F., Kayser, T., Horting, C., and Svendsen, B., Thermomechanical modeling and simulation of materials processing technology, (Journal name missed) 2009, no. 209, pp. 876–883.Google Scholar
  21. 21.
    Libura, W. and Rękas, A., Numerical modelling in designing aluminium extrusion, in: Aluminum Alloys: New Trends in Fabrication and Applications, Zaki Ahmad, Ed., In Tech, 2012, pp. 137–157. books/aluminium-alloys-new-trends-in-fabrication-and-applications/numerical-modelling-in-designing-aluminium-extrusion (accessed February 15, 2018).Google Scholar
  22. 22.
    Stebunov, S., Biba, N., Lishny, A., and Jiao, L., Practical implementation of numerical modeling to optimization of extrusion die design for production of complex shape profiles, Alum. Extrus. Finish., 2013, no. 4, pp. 20–24.Google Scholar
  23. 23.
    Kargin, V.R., Bykov, A.P., Kargin, B.V., and Erisov, Ya.A., Modelirovanie protsessov obrabotki metallov davleniem v programme DEFORM-2D (Simulation of Metal Forming Processes in the DEFORM-2D Program), Samara: MIR, 2010.Google Scholar
  24. 24.
    Sawtell, R.R. and Staley, J.T., Interactions between quenching and aging in allow 7075, J. Alum., 1983, no. 2, pp. 127–133.Google Scholar
  25. 25.
    Adler, Yu.P., Markova, E.V., and Granovskii, Yu.V., Planirovanie eksperimenta pri poiske optimal’nykh uslovii (Planning an Experiment when Searching for Optimal Conditions), Moscow: Nauka, 1976.Google Scholar

Copyright information

© Allerton Press, Inc. 2018

Authors and Affiliations

  1. 1.Samara National Research UniversitySamaraRussia
  2. 2.AO “Arconik SMZ”SamaraRussia

Personalised recommendations