Skip to main content
SpringerLink
Log in

Modeling of extrusion process of a condenser tube for investigating the effects of mandrel geometry

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In extrusion industry, optimization of die design plays a critical role in contributing to the quality of the extruded profile as well as tooling life. This study addresses the fact that most dies today are typically designed following a trial and error approach based on empirical knowledge of the designer, which inevitably results in increasing scrap rate and cost. The purpose is to understand the effects of geometry on the performance of a porthole die in order to improve the life of tooling and quality of the final extruded shape using finite element based simulations. In this work, a finite element (FE) model is developed to simulate the extrusion of a commercial grade aluminum alloy to produce a condenser tube used for cooling systems. Using the Update Lagrange FE analysis first, the tooling components of the modular die are assumed to be rigid in order to achieve the right friction coefficients to validate the experimental data collected during trail runs of the modular die. Next, DOE is used to identify the relative influence of the three main parameters that control the geometry of the mandrel. For each parametric set, a steady-state FE analysis is run to predict the maximum weld pressure between the mandrel port webs. The insight gained from these simulations is used to optimize the mandrel geometry.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Flitta I, Sheppard T (2005) Material flow during the extrusion of simple and complex cross-sections using FEM. J Mater Sci Technol 21(6):648–656

  2. Ceretti E, Mazzoni L, Giardini C (2007) 3D FEM geometry and material flow optimization of porthole-die extrusion. AIP Conference Proceedings 908(1): 419–424

  3. Ceretti E, Mazzoni L, Giardini C (2009) Simulation of metal flow and welding prediction in porthole die extrusion: the influence of the geometrical parameters. Int J Mater Form 2(1):101–104

    Article  Google Scholar 

  4. Chen H et al (2010) Numerical simulation of extrusion process and die structure optimization for a hollow aluminum profile with thin wall. Jixie Gongcheng Xuebao/Journal of Mechanical Engineering 46(24):34–39

    Article  Google Scholar 

  5. Fang K-T, Li R, Sudjianto A (2006) Design and modeling for computer experiments. computer science and data analysis series, ed. T.F. Group. Chapman & Hall/CRC

  6. Fang G, Zhou J, Duszczyk J (2009) Extrusion of 7075 aluminium alloy through double-pocket dies to manufacture a complex profile. J Mater Process Technol 209(6):3050–3059

    Article  Google Scholar 

  7. Lee JM, Kim BM, Kang CG (2005) Effects of chamber shapes of porthole die on elastic deformation and extrusion process in condenser tube extrusion. Mater Des 26(4):327–336

    Article  Google Scholar 

  8. Zhang C et al (2012) Numerical simulation and metal flow analysis of hot extrusion process for a complex hollow aluminum profile. Int J Adv Manuf Technol 60(1–4):101–110

    Article  Google Scholar 

  9. Lee SH et al (2008) Process analysis and die design in 12 cells condenser tube extrusion of Al3003. J Mater Process Technol 201(1–3):53–59

    Article  Google Scholar 

  10. Tang D et al (2014) Effect of die design in microchannel tube extrusion. Procedia Engineering 81(0):628–633

    Article  Google Scholar 

  11. He Y-F et al (2010) FEM simulation of aluminum extrusion process in porthole die with pockets. Trans Nonferrous Metals Soc China 20(6):1067–1071

    Article  Google Scholar 

  12. Wang L, Yang H (2012) Friction in aluminium extrusion—part 2: a review of friction models for aluminium extrusion. Tribol Int 56(0):99–106

    Article  Google Scholar 

  13. Sheppard IFT (2003) Nature of friction in extrusion process and its effect on material flow. Mater Sci Technol 19(7):837–846

    Article  Google Scholar 

  14. Wang L (2012) Modeling of friction for high temperature extrusion of aluminum alloys, Master of Engineering. Harbin Institute of Technology

  15. Saha PK (1998) Thermodynamics and tribology in aluminum extrusion. Wear 218(2):179–190

    Article  Google Scholar 

  16. Donati L, Tomesani L (2004) The prediction of seam welds quality in aluminum extrusion. J Mater Process Technol 153–154(0):366–373

    Article  Google Scholar 

  17. Liu J et al (2010) Effects of process parameters and die geometry on longitudinal welds quality in aluminum porthole die extrusion process. J Cent S Univ Technol 17(4):688–696

    Article  Google Scholar 

  18. Akeret R (1972) Properties of pressure welds in extruded aluminum alloy sections. J Inst Met 10:202–210

  19. Taylor L (ed) (1961) Metals Handbook: 8th edition, Vol. 1 - Properties and selection of metals. American Society of Metals. Ohio

Download references

Author information

Authors and Affiliations

  1. Indiana University—Purdue University Indianapolis, Indianapolis, IN, USA

    Tushar Bakhtiani, Hazim El-Mounayri & Jing Zhang

Authors
  1. Tushar Bakhtiani
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hazim El-Mounayri
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jing Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hazim El-Mounayri.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Bakhtiani, T., El-Mounayri, H. & Zhang, J. Modeling of extrusion process of a condenser tube for investigating the effects of mandrel geometry. Int J Adv Manuf Technol 92, 3237–3252 (2017). https://doi.org/10.1007/s00170-017-0374-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-0374-2

Keywords

Search

Navigation