Method for Pocket Die Design on the Basis of Numerical Investigation of Aluminium Extrusion Process

The paper considers dependencies of metal forming characteristics on dimensionless geometrical parameters of flat pocket die design at direct extrusion of aluminium thin-walled solid profiles. The theoretical analysis of plastic metal flow is carried out by means of the 2 -D FEM model. The new method for flat pocket die design is proposed in the paper. The die design example is given for non -symmetrical U-shape profile

Method for Pocket Die Design on the Basis of Numerical Investigation of Aluminium Extrusion Process

The paper considers dependencies of metal forming characteristics on dimensionless geometrical parameters of flat pocket die design at direct extrusion of aluminium thin-walled solid profiles. The theoretical analysis of plastic metal flow is carried out by means of the 2 -D FEM model. The new method for flat pocket die design is proposed in the paper. The die design example is given for non -symmetrical U-shape profile

Sinking of Ultra-Thick-Walled Double-Layered Aluminium Tubes

This work deals with the tube sinking process. The main purpose is to develop a process chain for the manufacturing of ultra-thick-walled tubes with the lowest possible diameter. The base material is a hot extruded tube consisting the aluminium alloy AA6063 with the dimensions 9,9 ×1 mm. The drawing tools include several dies with various exit holes, a drawing bench and a muffle oven to produce ultra-thick-walled tubes with dimensions 5,02…5,03 × 1,54…1,59 mm. The process has been applied successfully. With a double-layered tube, it was possible to reach a low diameter/wall-thickness ratio of 3,3 at tube sinking process. Subsequent pull-out tests showed that by reaching the threshold outer tube diameter value of Ø 5 mm the joining strength increased from 1,3 MPa to 6,2 MPa. It could be observed that the heat treatment reduced the joining strength for the double-layered tubes with diameter of 5 mm, whereupon for the bigger tubes diameter it has no significant influence on the joining strength

Fatigue crack growth behavior and mechanical properties of additively processed EN AW-7075 aluminium alloy

AbstractSelective Laser Melting (SLM®), an additive manufacturing (AM) technology, allows manufacturing of geometrically complex metallic parts directly. In the SLM technology, a high energy laser beam is applied to melt a thin layer of the metallic powder according to the information provided by CAD files. This layer-wise manufacturing offers the opportunity to create complex parts for application areas e.g., aerospace and automotive industries where the lightweight design has been and still is a priority for material development in recent years. Therefore, the materials such as aluminium alloys come into focus due to their low density and high mechanical characteristics. In view of these aspects, previously unused high strength aluminium alloy EN AW-7075 powder was produced by gas atomization and processed by SLM® as presented in this paper. Initially, specimens were produced to examine monotonic and fracture mechanical properties in different building directions. The tensile tests and the fracture examinations show an anisotropic material behaviour. The fatigue crack growth curves have the double S shape, which is typical of aluminium. Mechanical characteristics obtained from the experiments are lower in comparison to the conventionally manufactured aluminium alloy properties