Nature of friction in the extrusion process and its effect on material flow

This investigation focuses on simulation of the extrusion process and in particular the effect of the initial billet temperature on friction and its consequences on material � ow. The simulation is compared with data obtained from an experimental extrusion press. All the simulations are performed with the implicit Ž nite element codes FORGE2 and FORGE3. The effect of the initial billet temperature on the deformation zone pattern and its consequent effect on friction using both numerical simulation and experimental work are presented. A comparison with experiments is made to assess the relative importance of some extrusion parameters in the extrusion process and to ensure that the numerical discretisation provided a true simulation of the process. A speciŽ c functional relationship to directly measure interfacial friction under conditions approaching those encountered in the quasi-static deformation process is described. The results revealed that the friction factor increases with increase in initial billet temperature and varies from 0.65 at 300°C to a 0.91 at 450°C after reaching the peak pressure. The dead metal zone is observed to vary in form and has a greater volume at high temperatures. The increase in friction results in an increase of initial extrusion load. The Ž nite element program appears to predict all the major characteristics of the � ow observed macroscopically

Simulation of bridge die extrusion using the finite element method

This communication reviews previous work on the extrusion of hollow shapes and uses a three-dimensional (FEM) solution to predict load-required, temperature of the extrudate and material flow during the process. A comparison with experiments is made to assess the relative importance of some extrusion parameters in the extrusion process and to ensure that the numerical discretisation yields a realistic simulation of the process. The usefulness and limitations of FEM when modelling complex shapes is also discussed. Methods to assess the difficulty of extrusion of hollow extrusions in general are presented. The paper also illustrates the essentials of numerical analysis to assist the reader in the comprehension of the thermomechanical events occurring during extrusion through bridge dies. Results are presented for velocity distribution in the extrusion chamber, iso-temperature contours and pressure/ displacement traces. These are compared with experiments conducted using a 5 MN press. It is shown that the finite element program predicts the pressure requirement: the pressure/displacement trace showing a double peak which is discussed in some detail. The finite element program appears to predict all the major characteristics of the flow observed macroscopically

The effect of pressure and temperature variations on the FEM prediction of deformation during extrusion

The extrusion process is complex, involving interaction between the process variables and the material’s high temperature properties and is typically conducted at relatively high temperatures because the lower flow stress of the material permits larger section reductions to be achieved. This lowers the power requirements and processing times. Temperature is, perhaps, the most important parameter in extrusion. The flow stress is reduced if the temperature is increased and deformation is, therefore, easier, but at the same time, the maximum extrusion speed is reduced because localised temperatures must be well below any incipient melting temperature. The present investigation focuses on the evolution of the temperature in the billet from upsetting and until the end of the extrusion cycle is reached. The extrusion pressure and the temperature rise are predicted and the pressure–displacement trace and the events which take place in the deformed material during the extrusion process are also simulated. The simulation is compared with data obtained from an experimental extrusion press. All simulations are performed with the implicit finite element code FORGE2. A comparison with experiments is made to validate the predicted temperatures readings from FORGE2 to ensure that the numerical discretisation provides a true simulation of the process. It was found that the extrusion parameters (friction, heat transfer, etc.) are significantly influenced by the temperature gradients produced in the billet during transfer to the container, and after upsetting in the container. These parameters are thus clearly extremely sensitive input data when attempting to simulate the extrusion process

A study on surface cracking in extrusion of aluminium alloy AA2014

Surface cracking is generally recognised as one of the main defects occurring during the process of aluminium extrusion, especially in the case of the so called hard aluminium alloys. Previous experiments suggest that this type of defect is caused by the rise in temperature as the process proceeds. Some experiments indicate that the surface quality is good even though the temperature may be high during extrusion. It is also well known that crack criteria have been adopted to explain the cracking that occurs in extrusion, blanking and rolling, etc. In this study, a finite element method (FEM) is used in different ways to predict surface cracking during hot extrusion. The crack criteria are integrated into the FEM code FORGE12.0. The effectiveness of these criteria in predicting surface cracking in the case of hot extrusion is discussed. The FEM simulation also provides some other quantitative data, such as the temperature rise during extrusion from different initial temperatures. In addition, the principal stresses at the die land area at different extrusion stages are also shown

The potential impact on Florida-based marina and boating industries of a post-embargo Cuba: an analysis of geographic, physical, policy and industry trends

The information in this Technical Paper addresses the future of the US-Cuban marina and recreational boating industries from the geographic, physical, policy making and economic perspectives for a post-embargo Cuba. Each individual paper builds on the presentations made at the workshop, the information obtained in the subsequent trip to Cuba and presents in detailed form information which we hope is useful to all readers. (147pp.

Sodium-based hydrides for thermal energy applications

Concentrating solar–thermal power (CSP) with thermal energy storage (TES) represents an attractive alternative to conventional fossil fuels for base-load power generation. Sodium alanate (NaAlH4) is a well-known sodium-based complex metal hydride but, more recently, high-temperature sodium-based complex metal hydrides have been considered for TES. This review considers the current state of the art for NaH, NaMgH3-xFx, Na-based transition metal hydrides, NaBH4 and Na3AlH6 for TES and heat pumping applications. These metal hydrides have a number of advantages over other classes of heat storage materials such as high thermal energy storage capacity, low volume, relatively low cost and a wide range of operating temperatures (100 °C to more than 650 °C). Potential safety issues associated with the use of high-temperature sodium-based hydrides are also addressed

Novel synthesis of porous aluminium and its application in hydrogen storage

A novel approach for confining LiBH4 within a porous aluminium scaffold was applied in order to enhance its hydrogen storage properties, relative to conventional techniques for confining complex hydrides. The porous aluminium scaffold was fabricated by sintering NaAlH4, which was in the form of a dense pellet, under dynamic vacuum. The final product was a porous aluminium scaffold with the Na and H2 having been removed from the initial pellet. This technique contributed to achieving highly dispersed LiBH4 particles that were also destabilised by the presence of the aluminium scaffold. In this study, the effectiveness of this novel fabrication method of confined/destabilised LiBH4 was extensively investigated, which aimed to simultaneously improve the hydrogen release at lower temperature and the kinetics of the system. These properties were compared with the properties of other confined LiBH4 samples found in the literature. As-synthesised samples were characterised using Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD) and Nitrogen Adsorption measurements. The hydrogen storage capacity of all samples was analysed using temperature programmed desorption in order to provide a comprehensive survey of their hydrogen desorption properties. The porous aluminium scaffold has a wide pore size distribution with most of the porosity due to pores larger than 50 nm. Despite this the onset hydrogen desorption temperature (Tdes) of the LiBH4 infiltrated into the porous aluminium scaffold was 200 °C lower than that of bulk LiBH4 and 100 °C lower than that of nanosized LiBH4. Partial cycling could be achieved below the melting point of LiBH4 but the kinetics of hydrogen release decreased with cycle number

Why Do Situational Interviews Predict Performance? Is it Saying How You Would Behave or Knowing How You Should Behave?

Purpose: The present study examined two theoretical explanations for why situational interviews predict work-related performance, namely (a) that they are measures of interviewees’ behavioral intentions or (b) that they are measures of interviewees’ ability to correctly decipher situational demands. Design/Methodology/Approach: We tested these explanations with 101 students, who participated in a 2-day selection simulation. Findings: In line with the first explanation, there was considerable similarity between what participants said they would do and their actual behavior in corresponding work-related situations. However, the underlying postulated mechanism was not supported by the data. In line with the second explanation, participants’ ability to correctly decipher situational demands was related to performance in both the interview and work-related situations. Furthermore, the relationship between the interview and performance in the work-related situations was partially explained by this ability to decipher situational demands. Implications: Assessing interviewees’ ability to identify criteria might be of additional value for making selection decisions, particularly for jobs where it is essential to assess situational demands. Originality/Value: The present study made an effort to open the ‘black box’ of situational interview validity by examining two explanations for their validity. The results provided only moderate support for the first explanation. However, the second explanation was fully supported by these results