Journal Article

Energy analysis of the extrusion process through a streamlined Gaussian die

Liu, Xin Ying, Zhang, Shun Hu, Zhang, Yi

2023

Overview

Currently, the extrusion process with traditional conical die or elliptic die will cause the problems of high energy consumption and stress concentration. In order to address these problems, a novel streamline die characterized by the Gaussian function is designed first. The corresponding velocity field is constructed on the basis of the condition of equal flow per second. By using the newly constructed velocity field, the energy analysis of the extrusion is conducted, and the concrete internal work rate of plastic deformation, shearing work rate, and work rate of friction are obtained by a new method, called the feature-fitting substituting method. Then, the analytical expressions of extrusion force and stress state coefficient are obtained by the upper bound method. Simultaneously, the finite element (FE) simulation is conducted to verify the accuracy of the analytical expression of extrusion force and to disclose the advantages of the present die over the existing dies. The results show that the extrusion forces obtained from the present die match well with the simulation results, and the maximum deviation is no more than 1.73%. Above all, it is proved that the present Gaussian die can consume less energy and reduce the possibility of die loss evidently.

• Publisher: Springer Nature B.V
• Subject: Energy consumption / Extrusion dies / Extrusion rate / Finite element method / Mathematical analysis / Plastic deformation / Shearing / Stress concentration / Upper bounds / Velocity distribution