Newest developments on the manufacture of helical profiles by hot extrusion
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In: Journal of Manufacturing Science and Engineering, Vol. 133, No. 6, 061010, 12.2011.
Research output: Journal contributions › Journal articles › Research › peer-review
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TY - JOUR
T1 - Newest developments on the manufacture of helical profiles by hot extrusion
AU - Ben Khalifa, Noomane
AU - Tekkaya, A. Erman
PY - 2011/12
Y1 - 2011/12
N2 - A new innovative direct extrusion process, helical profile extrusion (HPE) is presented, which increases the flexibility of aluminum profile manufacturing processes. The application fields of such profiles can be seen in screw rotors for compressors and pumps. The investigations concentrate on experimental and numerical analyses by 3D-FEM simulations to analyze the influence of friction and the material flow on the twisting angle and contour accuracy. By means of finite-element method (FEM), the profile shape could be improved by modifying the die design. The numerical results were validated by experiments. For these investigations, a common aluminum alloy AA6060 was used. Mainly, the friction in the die influences the twist angle and the shape of the helical profile. Two die coatings were analyzed, but the friction was not substantially decreased in any of these cases. Although there is no efficient practical solution for reducing the friction in extrusion dies using tested die coatings, the required profile contour could be achieved by new die designing and by modifying the material flow. However, increasing the twist angle is limited due to geometrical aspects of this technology, namely, by the ratio of the volume to the contact area with the die for the displaced metal.
AB - A new innovative direct extrusion process, helical profile extrusion (HPE) is presented, which increases the flexibility of aluminum profile manufacturing processes. The application fields of such profiles can be seen in screw rotors for compressors and pumps. The investigations concentrate on experimental and numerical analyses by 3D-FEM simulations to analyze the influence of friction and the material flow on the twisting angle and contour accuracy. By means of finite-element method (FEM), the profile shape could be improved by modifying the die design. The numerical results were validated by experiments. For these investigations, a common aluminum alloy AA6060 was used. Mainly, the friction in the die influences the twist angle and the shape of the helical profile. Two die coatings were analyzed, but the friction was not substantially decreased in any of these cases. Although there is no efficient practical solution for reducing the friction in extrusion dies using tested die coatings, the required profile contour could be achieved by new die designing and by modifying the material flow. However, increasing the twist angle is limited due to geometrical aspects of this technology, namely, by the ratio of the volume to the contact area with the die for the displaced metal.
KW - Engineering
KW - aluminium alloys
KW - aluminium manufacture
KW - compressors
KW - extrusion
KW - finite element analysis
KW - friction
KW - pumps
KW - rotors
UR - http://www.scopus.com/inward/record.url?scp=82955188090&partnerID=8YFLogxK
U2 - 10.1115/1.4005116
DO - 10.1115/1.4005116
M3 - Journal articles
AN - SCOPUS:82955188090
VL - 133
JO - Journal of Manufacturing Science and Engineering
JF - Journal of Manufacturing Science and Engineering
SN - 1087-1357
IS - 6
M1 - 061010
ER -