Simulation of the Final Stage of the Direct Extrusion Method of Large-Size Rods at Small Elongations

Abstract

A simulation of the direct extrusion method of large-size rods with diameters of 188, 214, 252, 283, 326, and 560 mm made of alloy 7075; coefficients of friction of 0 and 0.5; and die cone angles of 80° and 90° from a container with a diameter of 800 mm using a 200-MN press with the help of the DEFORM-2D software package is performed. The distribution of radial velocities of metal flow on a working surface of a pressure pad depending on the contact friction, die cone angle, and elongation ratio at the main and final stages of extrusion is found. The butt-end height at the beginning instant of funnel formation is accepted equal to the distance between the pressure pad plane and input plane of extruded metal into a screw channel of flat or cone dies. The combined effect of the elongation ratio, coefficient of friction, and die cone angle on the butt-end height, extrusion force, intensities of strain rates and stresses, and temperature on the die orifice edge is investigated. Numerical experiments are performed according to the complete factorial plan 2³ for variability intervals of parameters: Х₁ = 3–9, Х₂ = 0–0.5, Х₃ = 80°–90°. Friction between the tool and the billet at the final stage of extrusion plays a negative role, noticeably decreasing the radial velocity. This leads to the earlier onset of the formation of the central funnel. Extrusion into a conical die and an increase in the elongation ratio, on the contrary, increase the radial flow velocity and provide the later onset of formation of a central funnel. The main factor that determines the butt-end height is the elongation ratio. A mathematical model is proposed to select the butt-end thickness for concrete extrusion conditions of large-dimensioned rods with small elongation ratios.