The die cooling by means of liquid nitrogen is a widely adopted industrial practice used to increase theproduction rate in the hot extrusion process of light alloys. The development of a reliable numerical modelable to simulate the cooling channel efficiency has become of primary interest for the extrusion sector inorder to avoid ineffective die cooling and time-consuming trials and errors. In this work, H13 die insertswith a helicoidally conformal channel were designed and printed by means of the SLM additive technology.Billets of AA6063 aluminum and ZM21 magnesium alloys were extruded at different process speeds undermonitored conditions to verify the insert resistance and the cooling effectiveness. A 3D finite element modelof the extrusion process coupled with a 1D model of the cooling channel was generated within the COMSOLsimulation environment. The experimental outputs were also used to validate the numerical predictions ofthe developed simulations. The FEM results showed a good matching with the loads and temperaturesobtained in the experimental trials. Moreover, the endurance of the AM tool validated the prediction of thestress field, thus proving the reliability of the numerical model for the application in the extrusion of lightalloys sector.

Extrusion of Light and Ultralight Alloys with Liquid Nitrogen Conformal Cooled Dies: Process Analysis and Simulation / Pelaccia, Riccardo; Negozio, Marco; Donati, Lorenzo; Reggiani, Barbara; Tomesani, Luca. - In: JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE. - ISSN 1059-9495. - 31:3(2022), pp. 1991-2001. [10.1007/s11665-021-06320-z]

Extrusion of Light and Ultralight Alloys with Liquid Nitrogen Conformal Cooled Dies: Process Analysis and Simulation

Pelaccia, Riccardo
;
Donati, Lorenzo;Reggiani, Barbara;Tomesani, Luca
2022

Abstract

The die cooling by means of liquid nitrogen is a widely adopted industrial practice used to increase theproduction rate in the hot extrusion process of light alloys. The development of a reliable numerical modelable to simulate the cooling channel efficiency has become of primary interest for the extrusion sector inorder to avoid ineffective die cooling and time-consuming trials and errors. In this work, H13 die insertswith a helicoidally conformal channel were designed and printed by means of the SLM additive technology.Billets of AA6063 aluminum and ZM21 magnesium alloys were extruded at different process speeds undermonitored conditions to verify the insert resistance and the cooling effectiveness. A 3D finite element modelof the extrusion process coupled with a 1D model of the cooling channel was generated within the COMSOLsimulation environment. The experimental outputs were also used to validate the numerical predictions ofthe developed simulations. The FEM results showed a good matching with the loads and temperaturesobtained in the experimental trials. Moreover, the endurance of the AM tool validated the prediction of thestress field, thus proving the reliability of the numerical model for the application in the extrusion of lightalloys sector.
2022
28-ott-2021
31
3
1991
2001
Extrusion of Light and Ultralight Alloys with Liquid Nitrogen Conformal Cooled Dies: Process Analysis and Simulation / Pelaccia, Riccardo; Negozio, Marco; Donati, Lorenzo; Reggiani, Barbara; Tomesani, Luca. - In: JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE. - ISSN 1059-9495. - 31:3(2022), pp. 1991-2001. [10.1007/s11665-021-06320-z]
Pelaccia, Riccardo; Negozio, Marco; Donati, Lorenzo; Reggiani, Barbara; Tomesani, Luca
File in questo prodotto:
Non ci sono file associati a questo prodotto.
Pubblicazioni consigliate

Licenza Creative Commons
I metadati presenti in IRIS UNIMORE sono rilasciati con licenza Creative Commons CC0 1.0 Universal, mentre i file delle pubblicazioni sono rilasciati con licenza Attribuzione 4.0 Internazionale (CC BY 4.0), salvo diversa indicazione.
In caso di violazione di copyright, contattare Supporto Iris

Utilizza questo identificativo per citare o creare un link a questo documento: https://hdl.handle.net/11380/1255222
Citazioni
  • ???jsp.display-item.citation.pmc??? ND
  • Scopus 4
  • ???jsp.display-item.citation.isi??? 3
social impact