Journal of Materials Processing Technology, 34 (1992) 101-108

Elsevier

101

Finite-element processes

analysis

of c o p p e r

extrusion

T. Reinikainen, K. Andersson, S. Kivivuori and A.S. Korhonen H e l s i n k l University of Technology, L a b o r a t o r y of Processing a n d Heat T r e a t m e n t of Materials, Vuorimiehentie 2 A, 02150 Espoo, Finland
Abstract

In t h i s work the finite-element s i m u l a t i o n of various copper extrusion processes was studied. Firstly the metal flow in a x i s y m m e t r l c extrusion was studied. Both flat-faced a n d converging dies were u s e d a n d the metal flow t h r o u g h t h e m w a s analyzed. The e x t r u s i o n w a s a s s u m e d to be i s o t h e r m a l . TWo d i f f e r e n t f r i c t i o n a l c o n d i t i o n s were s t u d i e d . The DEFORM f i n i t e - e l e m e n t p r o g r a m was u s e d to s i m u l a t e t h e e x t r u s i o n process. It was found t h a t results of the FEM simulation agreed well with the laboratory experimental results. S e c o n d l y the FEM s i m u l a t i o n of the Conform e x t r u s i o n process was s t u d i e d . The e x t r u s i o n w a s a s s u m e d to t a k e place u n d e r p l a n e s t r a i n conditions. It was found t h a t the filling of the extrusion c h a m b e r u p to the beginning of the extrusion could be simulated. The s h a p e of the steadystate deformation region could be calculated. Strain rates In the different p a r t s of the deformation region could be determined.
1. INTRODUCTION

There are several c o n t i n u o u s e x t r u s i o n p r o c e s s e s available for m a n u f a c t u r i n g different k i n d s of profiles. The b e s t k n o w n of t h e s e p r o c e s s e s are the Conform, Linex a n d H y d r o s p i n p r o c e s s e s [1,2]. The Conform process is today the m o s t widely u s e d process in the c o n t i n u o u s e x t r u s i o n of a l u m i n i u m , copper a n d their alloys. However, the m a t e r i a l flow in t h e Conform process is n o t y e t completely u n d e r s t o o d , a l t h o u g h model material experiments have been carried o u t b y Peng et al. [3]. In t h e c o n v e n t i o n a l e x t r u s i o n p r o c e s s e s the m a t e r i a l flow c a n be experimentally determined b y u s i n g either visio-plastic or model material m e t h o d s [4,5]. Nowadays m a t h e m a t i c a l s i m u l a t i o n m e t h o d s are widely u s e d in s i m u l a t i n g t h e m e t a l w o r k i n g p r o c e s s e s . T h e m o s t u s e d m a t h e m a t i c a l s i m u l a t i o n m e t h o d is the Finite-Element Method (FEM).
0924-0136/92/$05.00 1992 Elsevier Science Publishers B.V. AU rights reserved.

102 The t w o - d i m e n s i o n a l FEM program u s e d to simulate the metal flow in this s t u d y was DEFORM. To illustrate the feasibility of the finite-element m e t h o d in s i m u l a t i n g e x t r u s i o n and for verifying the reliability of the parameters, it is interesting to compare the results of the s i m u l a t i o n s to laboratory experiments. For this purpose c o n v e n t i o n a l forward e x t r u s i o n experiments were c o n d u c t e d and the material flow w a s compared to the respective simulations. In this work the FEM simulation of various copper e x t r u s i o n processes w a s studied. The t w o - d i m e n s i o n a l finite-element program Deform w a s u s e d to analyze the material flow in the area of deformation b o t h in the conventional extrusion processes and in the Conform process.
2
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//" j . 1 __T=

600.8~

__T=
~ T = __T=

788.00
750.80 800.88 ~SB .00

E S 8.599

___T:
__T= 8.299

___T =

908,00 950.00

0.800

- 0.000

] 0.320

0,640 RATE

0.36@

l - 1.280

101 I.E00

Figure i, The effect of strain rate and temperature o n the flow stress of 9 9 . 9 9 % copper.

2.

EXPERIMENTAL MATERIALS

AND M E T H O D S

The material u s e d in the forward extrusion experiments w a s 9 9 . 9 9 % pure copper. The initial diameter of the billets w a s 8 0 m m and the length 2 1 2 mm. The diameter of the e x t r u d e d rod w a s 3 2 mm. Before the experiments the billets were c u t in half along the plane of symmetry. A grid of 5 x 5 m m was g r o u n d o n one half of the billet, a n d the halves were thereafter a t t a c h e d together with two copper bolts. Graphite was u s e d between the halves to prevent a d h e s i o n during extrusion.

103 T h e e x p e r i m e n t s w e r e c a r r i e d o u t w i t h a 6 . 4 MN e x t r u s i o n p r e s s u s i n g b o t h f i a t - f a c e d a n d c o n v e r g i n g dies h a v i n g a die a n g l e of 7 8 . G r a p h i t e w a s u s e d a s a l u b r i c a n t in t h e e x t r u s i o n c h a m b e r a n d in t h e die. B e f o r e e x t r u s i o n t h e billets w e r e h e a t e d u p for 3 0 m i n u t e s a t 5 0 0 C o r 6 5 0 C a c c o r d i n g to w h e t h e r t h e y w e r e to b e e x t r u d e d w i t h a c o n v e r g i n g o r a f i a t - f a c e d die. In all t h e e x p e r i m e n t s t h e t e m p e r a t u r e of t h e e x t r u s i o n c h a m b e r w a s 5 0 0 C . T h e r a m s p e e d w a s 3 0 m m / s .

3.

FEM

MODELLING

For t h e s i m u l a t i o n of t h e e x t r u s i o n p r o c e s s e s , t h e f i n i t e - e l e m e n t c o d e D E F O R M w a s u s e d . T h e s i m u l a t i o n r u n s w e r e d o n e w i t h a Digital VAX S t a t i o n 3 1 0 0 c o m p u t e r . T h e f o r m u l a r e l a t i n g flow s t r e s s o f 9 9 . 9 9 % c o p p e r to s t r a i n r a t e a n d t e m p e r a t u r e h a d b e e n d e t e r m i n e d b y t o r s i o n t e s t s [6].

(1)
I n t h e f o r m u l a , t h e p a r a m e t e r s were A I = 3 . 8 0 5 5 8 x 10 "3, A2 = 3 . 1 3 3 3 4 x 10 -2 a n d A 3 = 7 . 6 9 4 5 9 . In addition, a o = 1 N / m m 2 and e = 2.71828. A graphical representation of t h e flow s t r e s s is s h o w n in Fig. 1. I n t h e s i m u l a t i o n of f o r w a r d e x t r u s i o n , t h e d e f o r m a t i o n w a s a s s u m e d to b e a x i s y m m e t r i c a n d i s o t h e r m a l . T h e d i a m e t e r of t h e billet w a s 8 0 m m a n d t h e l e n g t h 7 5 m m . T h e billet w a s a s s u m e d to b e s h o r t e r t h a n in t h e e x p e r i m e n t s so t h a t fewer e l e m e n t s c o u l d be u s e d . T h e e x t r u s i o n s p e e d was 30 m m / s and step i n c r e m e n t 0,05 mm. The extrusion t e m p e r a t u r e w a s e i t h e r 5 0 0 C or 6 5 0 C. O n t h e i n t e r f a c e b e t w e e n t h e billet a n d t h e e x t r u s i o n c h a m b e r , a friction f a c t o r m = 0,1 or m = 0,5 w a s u s e d . I n t h e m o d e l l i n g of t h e C o n f o r m p r o c e s s t h e d e f o r m a t i o n w a s a s s u m e d to t a k e p l a c e u n d e r p l a n e s t r a i n c o n d i t i o n s . T h e d e f o r m a t i o n e n e r g y w a s t r a n s f e r r e d to t h e b i l l e t b y a f r i c t i o n a l p l a n e w h i c h w a s m o v i n g d o w n w a r d s . T h e s p e e d of t h e p l a n e w a s 73 m m / s . T h e f r i c t i o n a l f o r c e o p e r a t i n g b e t w e e n t h e p l a n e a n d t h e billet w a s d e t e r m i n e d b y t h e friction f a c t o r m = 0.9. T h e friction f a c t o r b o t h o n t h e i n t e r f a c e b e t w e e n t h e billet a n d t h e s h o e a n d t h e billet a n d t h e a b u t m e n t w a s m = 0.1. T h e d i m e n s i o n s of t h e billet w e r e 17 m m x 2 0 0 m m . T h e t h i c k n e s s of t h e e x t r u d e d m a t e r i a l w a s 9 m m a n d t h e t h i c k n e s s of t h e f l a s h w a s 1.8 m m . T h u s u n d e r p l a n e s t r a i n c o n d i t i o n s t h e e x t r u s i o n ratio w a s 1.9.

104

2 X10 0.803

0.421

t 0. 3 4 4

-8.726

1 . 10~ -0.0e6

I 0.3?6

Figure 2. Material flow w h e n t h e e x t r u s i o n c h a m b e r a n d die are lubricated w i t h g r a p h i t e (T = 5 0 0 C, m = 0.1).

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4.5S1

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l

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h t -2.?IS

-6. 347

9.980 -0. 005

I 0.35S

Figure 3. Material flow w h e n n o lubrication is u s e d (T = 5 0 0 C, m = 0.5).

105

1.3~0j
0.96~

e l g h t

0.632

-0. 8 3 6

8. 378 8.080

o . 334

Figure 4. Material flow w h e n t he e x t r u s i o n c h a m b e r and die are l ubri cat ed with g r a p h i t e (T = 650 C, m = 0.5).

4. 4.1

RESULTS

AND

DISCUSSION

Material flow in forward extrusion Figs. 2 to 4 r e p r e s e n t t he c o m p a r i s o n of t h e s i m u l a t e d m a t e r i a l flow w i t h t h e flow o b s e r v e d in t h e e x t r u s i o n e x p e r i m e n t s . In t h e e x p e r i m e n t s h o w n in Fig. 2, t he e x t r u s i o n c h a m b e r a n d t he die were l u b r i c a t e d with g r a p h i t e p r i o r to e x t r u s i o n . In t h e r e s p e c t i v e s i m u l a t i o n t h e friction factor m = 0.1 was used. In t h e e x p e r i m e n t s h o w n in Fig. 3 no l u b r i c a t i o n w a s a d d e d before e x t r u s i o n . However, t h e r e m u s t h a v e b e e n s o m e l u b r i c a n t left from t h e earlier e x t r u s i o n s b e c a u s e t he flow of material w as quite h o m o g e n e o u s . In t h e s i m u l a t i o n the friction factor m = 0.5 was used. T h e material flow in the e x t r u s i o n with the flat-faced die is s h o w n in Fig. 4. T h e s i m u l a t i o n w a s c o n d u c t e d j u s t u n t i l t h e s t e a d y s t a t e w as r e a c h e d to save c o m p u t a t i o n time. A l t h o u g h g r a p h i t e l u b r i c a t i o n w as u s e d , th e friction s e e m s to be quite high. T h e respective s i m u l a t i o n w as c o n d u c t e d u s i n g t h e friction factor 0.5. In Figs. 2 an d 3 it c a n be s e e n t h a t a c h a n g e in the frictional conditions affects t h e flow of m a t e r i a l s i m i l a r l y b o t h in FEM s i m u l a t i o n s a n d in e x p e r i m e n t s . W h e n f r i c t i on is low, d e f o r m a t i o n s t a r t s a f t e r m a t e r i a l e n t e r s th e die. W h e n friction is high, t he grid-lines s t a r t curvi ng a l r e a d y

106 before the die. By comparing the simulated and real extrusions in Fig. 3, it appears that a friction factor m --- 0.5 is obviously too high. A lower friction factor of 0 . 4 w o u l d probably have given better a g r e e m e n t b e t w e e n the simulation and measurements. In t h e e x p e r i m e n t s h o w n in Fig. 4, the area w h e r e t h e plastic deformation takes place is slightly smaller in the simulated extrusion t h a n in the real extrusion. Howeve,; the dead metal z o n e s have the s a m e form and are about equal in size. 4.2 The Conform process The flow of material at the b e g i n n i n g of the Conform process is s h o w n in Fig. 5. In Figs. 6 and 7 the effective strain and the effective strain rate distributions are s h o w n . The strain c o n t o u r s in Fig. 6 s h o w that the deformation in the die area resembles the deformation in forward extrusion. The strain is high on the surface and decreases towards the central axis of the product. With the given g e o m e t r y it s e e m s t h a t a part of the material w h i c h h a s g o n e t h r o u g h severe deformation in the a b u t m e n t area, e n d s u p in the centre of the product. The result is a h o m o g e n e o u s strain distribution in the final product.
1

1.769

b-

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o._<_~4

---

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vh. 2 f l 9

2k

r 8. 789 1 . 101

I 1 . 498

! 1 . 994

I 2. 275

~}!"-.

:,:1,

8.666

X-fix

I ~=.

Figure 5. Material flow in the Conform process.

107

Elf,
O=

Strain

A= 0.65376E-81
0.2GL~8 0. g57'89
E= F-

1.6454

19.3

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Figure 6. The effective strain distribution In the Conform process.

24.8 t

I C= 6,8888 D- 9.B888 E= 12.880 F= 15.088

14,1
o

E l f . Stn Rt Object I 4 O- 47.7BB ~= B. 43615E-I~3 Q" 0. 00880E +08 B= 3.8888

G= H= I-

24.800

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,
8,7
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.,'

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, ,

Is2
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18.
-axls

15

20

Figure 7. The effective strain rate distribution in the Conform process.

108
5. C O N C L U S I O N S

The flow of material in the FEM s i m u l a t i o n s of e x t r u s i o n agrees well with the experimental results. The a s s u m e d simplifications (isothermal d e f o r m a t i o n a n d c o n s t a n t friction factor) do n o t m a k e a considerable difference in the material flow. The FEM m e t h o d can be u s e d in designing the o p t i m u m area of deformation in the Conform process. By u s i n g FEM the s t r a i n a n d strain rate distributions c a n be optimized to increase tool life a n d to obtain good product quality.

6.

REFERENCES

1 2 3 4 5

Bauser, M., 31rschy, E., Strangpressen - neutiger S t a n d u n d Entwicklungstendezen. Z. Metallkunde 73 (1982)7 411. Green, D., "Hydrospin" - A new concept of extrusion. J. Inst. Metals 99 (1971) 76. Peng, D.S., Yao, B.Q., Zuo, TK., The experimental simulation of deformation behaviour of metals in the Conform process. J o u r n a l of Central-South Institute of Mining a n d Metallurgy 21 (1990) 492. Pihlainen, H., Kivivuori, S. and Kleemola, H., Die Design in the Extrusion of Hollow Copper Sections u s i n g the Model-Materials Technique. J. Mech. Work. Tech. 12 (1985)1 205. Kivivuori, S., A Model-Material Upsetting Method of Designing Extrusion Dies. Presented at the S y m p o s i u m on Physical Modelling of Metalworking Processes, the TMS-AIME A n n u a l Spring Meeting Feb. 24-27, 1987, Denver, USA. Published in the Proceedings of the S y m p o s i u m on Physical Modelling of Metalworking Processes, TMDAIME Shaping and Forming Committee, 1987. Beiss, P., Broichhausen, J., Formenderungstestigkeit yon Kupfer u n d Kuferlegierungen beim Strangpressen. Metall 31 (1977)11 1206.