Session: 03-08-02: Computational Modeling and Simulation for Advanced Manufacturing

Paper Number: 143348

143348 - Modeling and Simulation of 7000-Series Aluminum Extrusion Process for Complex Curtain Structure Profile 

Aluminum extrusion is a cornerstone metalworking process, but achieving complex profiles using high-strength 7000-series aluminum alloys (including AA7005 and AA7075 in this study) presents challenges. These alloys, while prized for their superior mechanical properties, exhibit lower formability compared to the more widely used 6000-series. Traditionally, die design for such complex extrusions has relied on a time-consuming and resource-intensive "test-and-revise" approach. This research uses a novel methodology that leverages simulation techniques to streamline this process for complex 7000-series extrusions. The key challenge lies in the inherent contradiction between the desirable mechanical strength of 7000-series alloys and their lower formability during extrusion. While extensive research exists on complex profile extrusion, it primarily focuses on the more readily extruded 6000-series. Conversely, studies on high-strength alloys often concentrate on simpler geometries due to the complexities associated with their superior mechanical properties. This study aims to bridge this knowledge gap by investigating the combined challenge of utilizing 7000-series alloys for complex profile extrusions.

To overcome the limitations of traditional methods, this study explores a simulation-based approach. The methodology involves two different but complementary simulation techniques: steady-state and transient-state analyses. Steady-state simulations, employing the finite element method (FEM), offer an efficient means to analyze the influence of design choices and process parameters on the extrusion process. This approach excels at evaluating the impact of different die configurations and extrusion parameters on factors such as front-end material flow and stress distribution within the die. However, a crucial limitation of steady-state simulations is their inability to capture all stages of the process, where transient material flow initiation and potential instabilities might occur. Therefore, the research incorporates transient-state simulations using the sfDytran solver within the Simufact Forming software. This simulation, based on the finite volume method (FVM), provides a more comprehensive understanding of the flow behavior of the material during the stages of extrusion. Transient simulations provide researchers with valuable insights into the flow characteristics and potential instabilities that might arise during the process, facilitating enhanced die design. Besides, the study also utilizes Altair Inspire Extrude, a software specifically designed for simulating metal extrusion processes using the finite element method. This software offers a comprehensive suite of tools for analyzing various complexities encountered in metal extrusion, including factors like the length of the bearing, profile complexity, or dies with multiple hole structures.

By combining the strengths of both steady-state and transient-state, this research approach provides a well-rounded understanding of material flow, maximum press force, and potential challenges within the die during the extrusion process. This knowledge empowers researchers to improve the die design for complex extrusions using high-strength 7000-series aluminum alloys. This ability to virtually analyze and optimize die design paves the way for significant advancements in the extrusion of complex profiles using high-strength aluminum alloys. The potential applications of this research extend to various industries that rely on lightweight, high-strength structural components, such as the construction and aerospace fields.

Presenting Author: Quang-Cherng Hsu National Kaohsiung University of Science and Technology

Presenting Author Biography: Dr. Quang-Cherng Hsu is currently a professor of Mechanical Engineering, National Kaohsiung University of Science and Technology (NKUST), Taiwan. Prof. Hsu earned his Ph.D. in Mechanical Engineering, National Cheng-Kung University in 1981. After two-year service in military, he joined Metal Industry Research and Development Center, a government-funded non-profit research organization, in Kaohsiung as a research engineer for about two years. Then, he joined the current University.
Prof. Hsu has published 64 referred journal papers, has obtained 16 invention patents and has attended 79 international conferences among 13 countries to present his research results. Prof. Hsu also likes to organize student’s handy-team to attend domestic professional competitions including: Industrial Robot Competition, Computer Aided Measurement and Verification Competition, Mold and Die Industrial Application and Innovation Competition, Image Servo and Precision Measurement Competition, Optical-Electronic Inspection Instrument Competition, and Precision Machinery Competition.

Authors:

Thanh-Cong Nguyen Department of Mechanical Engineering, National Kaohsiung University of Science and Technology
Quang-Cherng Hsu National Kaohsiung University of Science and Technology
Tat-Tai Truong Department of Mechanical Engineering, Hung Yen University of Technology and Education