Numerical simulation of friction extrusion: process characteristics and material deformation due to friction

IF 2.6 3区材料科学 Q2 ENGINEERING, MANUFACTURING

International Journal of Material Forming Pub Date : 2024-04-10 DOI:10.1007/s12289-024-01825-z

George Diyoke, Lars Rath, Rupesh Chafle, Noomane Ben Khalifa, Benjamin Klusemann

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Abstract

This study employs a finite element thermo-mechanical model, using a Lagrangian incremental setting to investigate friction extrusion (FE) under varying process conditions. The incorporation of rotation in FE generates substantial frictional heat, leading to significantly reduced process forces in comparison to conventional extrusion (CE). The model reveals the interplay between temperature, strain, and strain rate across different microstructural zones of the resulting wire. Specifically, the sticking friction condition in FE enhances initial shear deformation, aligning with a homogeneous spatial strain distribution and predicting complete grain refinement in the extruded wire, as per Zener-Hollomon calculations. On the other hand, under the sliding friction condition in FE, the shear deformation is reduced which results in an inhomogeneous microstructure in the extruded wire. The analysis of material flow in the workpiece reveals distinct transitions from the base material to the thermo-mechanically affected zones. The simulated process force, thermal history, and microstructure during sliding friction conditions align well with the findings from performed friction extrusion experiments.

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摩擦挤压的数值模拟：工艺特征和摩擦导致的材料变形

本研究采用有限元热机械模型，使用拉格朗日增量设置来研究不同加工条件下的摩擦挤压（FE）。与传统挤压（CE）相比，摩擦挤压中的旋转产生了大量摩擦热，从而显著降低了加工力。该模型揭示了温度、应变和应变率在所得线材的不同微观结构区域之间的相互作用。具体来说，FE 中的粘着摩擦条件增强了初始剪切变形，与均匀的空间应变分布相一致，并根据齐纳-霍洛蒙计算结果预测挤压线材中的晶粒会完全细化。另一方面，在 FE 的滑动摩擦条件下，剪切变形减小，导致挤压线材的微观结构不均匀。对工件中材料流动的分析表明，从基体材料到热机械影响区之间存在明显的过渡。滑动摩擦条件下的模拟加工力、热历史和微观结构与摩擦挤压实验的结果非常吻合。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Material Forming ENGINEERING, MANUFACTURING-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.10

自引率

4.20%

发文量

审稿时长

>12 weeks

期刊介绍： The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material. The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations. All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.