Numerical modelling of the aluminium extrusion process

The extrusion of aluminium alloys involves the shaping of the product from an homogenised billet into a complex shape. In addition the properties of the extrudate are closely related to the processing parameters (temperature, stain rate, and material morphology). Since all the parameters vary throughout the ram stroke and throughout the billet the prediction of the condition of the extrudate is complex. In this study the analysis is accomplished by the use of finite element analysis coupled with sub-illodelling of the structural features. The study is extended to include the lieat-treatment process necessary for precipitation hardened alloys subsequent to the process. The author has published these results in a number of learned journals and these are given in Appendix. After a concise introduction and crirical literature review chapter3 analyses the basic operation of the finite element package(FEM) discussing the procedures involved, the equilibrium equations and the more practical aspect of the mesh morphology and size. Finite Element analysis and material structural models have been integrated using parallel processing technology and program sub-routines. In this section the external inputs are also defined paying particular attention to the friction conditions and the constitutive equations. The thesis then proceeds to describe and analyse the integrated modelling of the process necessary to introduce the user introduction of the equations necessary to produce a comprehensive analysis of the material structural problems. This includes the cellular automata teclu-iiques. Various complex extrusion geometries are analysed and the effects of scaling considered. Development of the extrudate surface and criteria for ptedicting this important feature are coinprehebsivcly covered in chapter 5 whilst chapter 6 considers some special technologies such as the use of pockets to obtain homogenous structures. Isothermal extrusion is also included in this section

10th EASN International Conference on Innovation in Aviation & Space to the Satisfaction of the European Citizens

This Special Issue book contains selected papers from works presented at the 10th EASN (European Aeronautics Science Network) International Conference on Innovation in Aviation & Space, which was held from the 2nd until the 4th of September, 2020. About 350 remote participants contributed to a high-level scientific gathering providing some of the latest research results on the topic, as well as some of the latest relevant technological advancements. Eleven interesting articles, which cover a wide range of topics including characterization, analysis and design, as well as numerical simulation, are contained in this Special Issue

Numerical modelling of the aluminium extrusion process and comparison with results obtained from industrially extruded complex sections.

This thesis reports the analysis of extruded products by Forge2009® and EBSD produced by the investigator in the BOAL plant. The 3D FEM module was used to study the required load, the temperature evolution, surface formation of the extrudate and material flow during the process. The effect of varying process conditions on the selected geometries were investigated and verified by means of experiment. Considering the difficulty in performing the experiments (high temperature and high strain rates) the simulation results can be considered to be acceptable. The simulations were performed with the implicit finite element code Forge2009® with user input written in Visual Fortran®. Alloy EN AW-6082 was selected on the basis that is a commonly used extrusion material in industry. A range of simulations were designed which would produce differing structures to those experienced within the industry. The effect of variation of the bridge design for hollow dies and the effect of variation of the sink in for solid dies was investigated. 3D simulations were performed to investigate the effect of these variations in the design features on extrusion process parameters. The process parameters which are likely to be affected are load, deflection, velocity and temperature. The results indicated that the design of the die affected the process parameters. The microstructure evolution during the extrusion process was investigated for the selected complex geometries. The following microstructure features were included in the investigations: Recrystallised grain size, subgrain size, misorientation, dislocation density and volume fraction recrystallised. Simulations were performed using physically-based mathematical microstructure models integrated into FEM through its Fortran® subroutine interface. Experiments were performed to investigate the effects of varying process conditions on the microstructure. For hollow section, the emphasis was placed on the study of the complicated metal flow and the seam welding quality. EBSD analyses were performed to investigate the substructure. Surface cracking was modelled and compared with experiments. The agreement between the predicted microstructures using associated models and experimental measurements were acceptable. Predicted cracking show good correlation with experimental result

Numerical modelling of the aluminium extrusion process

The extrusion of aluminium alloys involves the shaping of the product from an homogenised billet into a complex shape. In addition the properties of the extrudate are closely related to the processing parameters (temperature, stain rate, and material morphology). Since all the parameters vary throughout the ram stroke and throughout the billet the prediction of the condition of the extrudate is complex. In this study the analysis is accomplished by the use of finite element analysis coupled with sub-illodelling of the structural features. The study is extended to include the lieat-treatment process necessary for precipitation hardened alloys subsequent to the process. The author has published these results in a number of learned journals and these are given in Appendix. After a concise introduction and crirical literature review chapter3 analyses the basic operation of the finite element package(FEM) discussing the procedures involved, the equilibrium equations and the more practical aspect of the mesh morphology and size. Finite Element analysis and material structural models have been integrated using parallel processing technology and program sub-routines. In this section the external inputs are also defined paying particular attention to the friction conditions and the constitutive equations. The thesis then proceeds to describe and analyse the integrated modelling of the process necessary to introduce the user introduction of the equations necessary to produce a comprehensive analysis of the material structural problems. This includes the cellular automata teclu-iiques. Various complex extrusion geometries are analysed and the effects of scaling considered. Development of the extrudate surface and criteria for ptedicting this important feature are coinprehebsivcly covered in chapter 5 whilst chapter 6 considers some special technologies such as the use of pockets to obtain homogenous structures. Isothermal extrusion is also included in this section.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Aeronautical engineering: A continuing bibliography with indexes (supplement 286)

This bibliography lists 845 reports, articles, and other documents introduced into the NASA scientific and technical information system in Dec. 1992. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment, and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Aeronautical engineering: A continuing bibliography with indexes (supplement 270)

This bibliography lists 600 reports, articles, and other documents introduced into the NASA scientific and technical information system in September, 1991. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Aeronautical engineering: A cumulative index to a continuing bibliography (supplement 274)

This publication is a cumulative index to the abstracts contained in supplements 262 through 273 of Aeronautical Engineering: A Continuing Bibliography. The bibliographic series is compiled through the cooperative efforts of the American Institute of Aeronautics and Astronautics (AIAA) and the National Aeronautics and Space Administration (NASA). Seven indexes are included: subject, personal author, corporate source, foreign technology, contract number, report number, and accession number

Advances in raw material industries for sustainable development goals

"""Advances in Raw Material Industries for Sustainable Development Goals"" presents the results of joint scientific research conducted in the context of the Russian-German Raw Materials Forum. Today Russia and Germany are exploring various forms of cooperation in the field of mining, geology, mineralogy, mechanical engineering and energy. Russia and Germany are equally interested in expanding cooperation and modernizing the economy in terms of sustainable development. The main theme of this article collection is connected with existing business ventures and ideas from both Russia and Germany. In this book the authors regard complex processes in mining industry from various points of view, including: - modern technologies in prospecting, exploration and development of mineral resources - progressive methods of natural and industrial mineral raw materials processing - energy technologies and digital technologies for sustainable development - cutting-edge technologies and innovations in the oil and gas industry. Working with young researchers, supporting their individual professional development and creating conditions for their mobility and scientific cooperation are essential parts of Russian-German Raw Materials Forum founded in Dresden 13 years ago. This collection represents both willingness of young researchers to be involved in large-scale international projects like Russian-German Raw Material Forum and the results of their long and thorough work in the promising areas of cooperation between Russia and Germany.

Developing a QFD-Based design-integrated structural analysis methodology

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Design of the mechanical components greatly depends on their expected structural performances. In modern design applications these performances are quantified by computer-based analysis and occasionally confirmed by experimental measurements or theoretical calculations. The dependency of the mechanical product to the structural analysis process is more significant under the product’s multi-functionality aspect that requires analyses for a variety of Variable Input Parameters, to obtain various structural responses and against more than one failure or design criterion. Structural analysis is known as the expert field, which requires an upfront investment and facilitation to be implemented in commercial design environment. On the other hand, the product design process is a systematic and sequential activity that put the designer in the central role of decision making. Lack of mutual understanding between these two disciplines reduces the efficiency of the structural analysis for design. This research aims to develop an integrated methodology to embed the structural analysis in the design process. The proposed methodology in this research combines the benefits of state-of-the-art approaches, early simulation and Validation and Verification practice, towards the specified aim. Moreover the novelty of the proposed methodology is in creative implication of Quality Function Deployment method to include the product’s multi-functionality aspect. The QFD-Based Design Integrated Structural Analysis methodology produces a reliable platform to increase the efficiency of the structural analysis process for product design purpose. The application of this methodology is examined through an industrial case-study for the telescopic cantilever boom, as it appears in Access platforms, and Cranes products. Findings of the case-study create a reliable account for the structural performance in early stages of the design, and ensure the functionality of the proposed methodology.This research programme was funded by KTP organisation

Aeronautical engineering: A continuing bibliography with indexes (supplement 271)

This bibliography lists 666 reports, articles, and other documents introduced into the NASA scientific and technical information system in October, 1991. Subject coverage includes design, construction and testing of aircraft and aircraft engines; aircraft components, equipment and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics