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Friction & Wear

An Investigation of Die Wear Behavior During Aluminum Alloy 7075 Tube Extrusion

[+] Author and Article Information
Cunsheng Zhang

Key Laboratory for Liquid-Solid Structural
Evolution and Processing of Materials
(Ministry of Education)
Shandong University
Jinan, Shandong 250061, P. R. C.
State Key Laboratory of Materials Processing
and Die & Mould Technology
Huazhong University of Science and Technology
Wuhan, Hubei 430074, P. R. C.
e-mail: zhangcs@sdu.edu.cn

Guoqun Zhao

e-mail: zhaogq@sdu.edu.cn

Tingting Li

e-mail: litingting198801@163.com

Yanjin Guan

e-mail: guan_yanjin@sdu.edu.cn

Hao Chen

e-mail: chenhao1984223@163.com
Key Laboratory for Liquid-Solid Structural
Evolution and Processing of Materials
(Ministry of Education)
Shandong University
Jinan, Shandong 250061, P. R. C.

Peng Li

CSR Qingdao Sifang Co. Ltd.
Qingdao, Shandong 266111, P. R. C.
e-mail: Lipeng@cqsf.com

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the Journal of Tribology. Manuscript received March 9, 2012; final manuscript received August 28, 2012; published online December 20, 2012. Assoc. Editor: Robert Wood.

J. Tribol 135(1), 011602 (Dec 20, 2012) (9 pages) Paper No: TRIB-12-1034; doi: 10.1115/1.4023081 History: Received March 09, 2012; Revised August 28, 2012

During hot extrusion process, die wear shortens markedly the service life of extrusion dies under the high-pressure, high-temperature conditions. In this paper, based on modified Archard's wear model, a user-defined subroutine for calculating die wear depth was developed and implanted into DEFORM-3D. On the basis of the numerical model, the die wear behavior during aluminum alloy 7075 tube extrusion has been investigated. The numerical results show that process variables have multiple effects on die wear behavior. With the increasing ram speed, wear depth of die bearing rises and then tends to decline gradually. From the ram speed of 15 mm/s, die wear depth begins to increase again. Wear depth rises suddenly with the increase of friction coefficient, then gradually reduces. When friction coefficient is greater than 0.8, wear depth tends to be a constant. A maximum wear depth occurs at 430 °C of billet temperature, and a minimum wear depth occurs at certain die temperature in the range of 400–425 °C. In addition, the required extrusion force has strong dependence on process variables. The extrusion force rises clearly with the increase of ram speed and friction coefficient and with the decrease of initial temperatures of billet and die.

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References

Figures

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Fig. 1

Extrusion die designed in this work (unit: mm)

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Fig. 2

1/8 model used in the numerical simulation

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Fig. 3

Flow stress curve of AA7075

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Fig. 4

Definition of friction window

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Fig. 5

Velocity distribution and node-end of the forming workpiece

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Fig. 6

Load-stroke curve at the ram speed of 1 mm/s

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Fig. 7

Metal flow states in different stages during extrusion process

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Fig. 8

Temperature distribution on extrusion die at a ram speed of 1.0 mm/s

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Fig. 9

Die temperature of measured points under various extrusion velocities

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Fig. 10

Maximum temperatures on the forming workpiece and extrusion die

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Fig. 11

Effects of ram speed on wear coefficient and die hardness

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Fig. 12

Effects of ram speed on interface pressure of measured points

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Fig. 13

Effects of ram speed on wear depth of measured points

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Fig. 14

Wear distribution on extrusion die at a ram speed of 1.0 mm/s

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Fig. 15

Effects of ram speed on maximum wear depth of die bearing

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Fig. 16

Effects of ram speed on required extrusion force

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Fig. 17

Effects of billet preheating temperature on maximum wear depth of bearing

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Fig. 18

Effects of die preheating temperature on maximum wear depth of bearing

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Fig. 19

Effects of friction coefficient on required extrusion force

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Fig. 20

Effects of friction coefficient on wear depth of bearing

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