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Prediction and analysis of breakthrough extruding force based on a modified FE-model in large-scale extrusion process

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Abstract

P91 steel is considered an appropriate material for high-quality pipes used in nuclear plant. In the extrusion process on 680-million-newton-tonnage forging and extruding machine to manufacture long seamless P91 pipes with large diameter and wall-thickness, the extruding force peak during the process will exceed 500 million newtons. For security consideration, prediction of extruding force, especially breakthrough force, must be accurate to avoid accidents like jamming. A modified finite element model has been developed to predict the extruding force in large-scale glass lubricant hot extrusion of P91 pipes and declare the relationship between the friction ratio and container temperature. On the basis of the practical extrusion results obtained on 360-million-newton-tonnage extruding machine and characteristics of large-scale extrusion, the billet cooling period and new viscous friction model on billet–container interface are added or established as the modification on the most significant sensitive factors. Using the modified model, the average temperature error after cooling is 3.23 °C and the maximum decrease of simulation results of breakthrough extruding force on 360-MN machine is 17 MN. The predicted results correspond to the decreasing tendency of the measured ones. The deviation between the simulated breakthrough extruding force and measured one on 680-MN machine is only 0.3%, which validates the accuracy of force-predicting model. This study may offer the basis for precise prediction for complete large-scale extrusion process and provide guidance to reduce the breakthrough force in the extrusion process.

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Acknowledgments

The authors are grateful to Inner Mongolia North Heavy Industry Group Corp. Ltd and Qinghai Kangtai Casting and Forging Machinery Corp. Ltd, for providing the production data and experimental equipment. And the authors are very grateful to all the reviewers and editors of the present paper, who gave very constructive comments and kind help.

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Authors and Affiliations

  1. Key Laboratory for Advanced Material Processing Technology, Ministry of Education, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, People’s Republic of China

    Yilin Jiang, Rendong Wu, Chaolong Yuan, Wenzhu Wang & Wei Jiao

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  1. Yilin Jiang
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  2. Rendong Wu
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  3. Chaolong Yuan
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  4. Wenzhu Wang
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  5. Wei Jiao
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Contributions

YLJ, RDW, CLY, WZW, and WJ were involved in designing experiments, carrying out experiments, developing the simulation model, and analyzing the results. RDW designed and modified the manuscript. All authors read and approved the final manuscript.

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Correspondence to Rendong Wu.

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Jiang, Y., Wu, R., Yuan, C. et al. Prediction and analysis of breakthrough extruding force based on a modified FE-model in large-scale extrusion process. Int J Adv Manuf Technol 104, 3531–3544 (2019). https://doi.org/10.1007/s00170-019-04039-9

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  • DOI: https://doi.org/10.1007/s00170-019-04039-9

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