Three-dimensional fluid-thermal-structure multiphysics interaction simulation model of aluminium extrusion process

Authors

  • Maher A. R. Sadiq Al-Baghdadi Department of Mechanical Engineering, Faculty of Engineering, University of Kufa, Najaf, Iraq. Mobile: +9647719898955; Phone: +96433340952; Fax: +96433340951 https://orcid.org/0000-0002-9172-8771
  • Muhannad Al-Waily Department of Mechanical Engineering, Faculty of Engineering, University of Kufa, Najaf, Iraq. Mobile: +9647719898955; Phone: +96433340952; Fax: +96433340951 https://orcid.org/0000-0002-7630-1980

DOI:

https://doi.org/10.15282/jmes.15.3.2021.04.0648

Keywords:

Aluminium extrusion, CFD, Multiphysics, Fluid-thermal-structure interaction, Three-dimensional model, Stress

Abstract

Three dimensional fluid-thermal-structure multiphysics interaction simulation model of aluminium extrusion process has been simulated and presented in this paper. This multiphysics complex geometrical engineering process is simulated effectively using computational fluid dynamics (CFD) simulation with very high accuracy, where the aluminium material is treated as a fluid that has a very high viscosity which depends on temperature and velocity. When aluminium moving, the inner friction will work as a heat source, therefore the model of the heat transfer is completely coupled together with those governing model of the fluid dynamics. Material properties come into a viscosity function that can be related to the flow stress locally depending on forming velocity and temperature. In addition, the stresses distribution in the die that introduces due to the fluid pressure and the thermal loads has been modelled by fully coupled the simulation model with the structural mechanic's analysis. Fully three-dimensional results during the process of the temperature distribution, velocity profile, von Mises stress distribution, total displacement and deflection distribution, equivalent volumetric strain distribution, and pressure distribution are presented and analysed with a focus on the fundamental understanding. The model is shown to be able to provide a computer-aided design tool for optimize this complex engineering process by improving productivity and reducing scrap.

Author Biographies

Maher A. R. Sadiq Al-Baghdadi, Department of Mechanical Engineering, Faculty of Engineering, University of Kufa, Najaf, Iraq. Mobile: +9647719898955; Phone: +96433340952; Fax: +96433340951

Asst. Prof. Maher A.R. Sadiq Al-Baghdadi is a lecturer in the Kufa University, Faculty of Engineering.  He has published many academic and industrial oriented papers and books. His research interests include fuel cell technology; computational fluid dynamics (CFD); renewable energy; alternative fuels; and energy and environmental impact.

Contact: mahirar.albaghdadi@uokufa.edu.iq

Muhannad Al-Waily, Department of Mechanical Engineering, Faculty of Engineering, University of Kufa, Najaf, Iraq. Mobile: +9647719898955; Phone: +96433340952; Fax: +96433340951

Asst. Prof. Dr. Muhannad Al-Waily, Lecturer at Mechanical Engineering Department, Faculty of Engineering , Al-Kufa University. Ph.D. In Mechanical Engineering/College of Engineering / Alnahrain University /Iraq. • Specialization: Applied Mechanics- Vibration Analysis, Composite Material, Crack Analysis, Health Monitoring, Graduation Date: 2012. M.Sc. In Mechanical Engineering/ College of Engineering/University of Kufa/Iraq • Specialization: Applied Mechanics- Vibration Analysis, Composite Material, Stress Analysis, Graduation Date: 2005. B.Sc. In Mechanical Engineering/ College of Engineering/University of Kufa /Iraq • Specialization: General Mechanics, Graduation Date: 2002.

Research Interests, Vibration Engineering Analysis Study, Plate and Shell Study, Vibration Beam, Plate, Shell Analysis, Stress Analysis Study under Static and Dynamic Loading, Buckling Analysis Study, Composite Materials Study, Fatigue Analysis Study of Engineering Materials, Mechanical Properties of Engineering Materials Study, Control and Stability of Mechanical Application Study, Damage Study (Crack and Delamination Study), Flow Induced Vibration of Pipe, Heat Generation due to Vibration Effect, Rubber Material Study, Prosthetic and Orthotics Study, Friction Stir Welding Study, and other mechanical researches.

Associate Editors, Applied Mechanics Research Center, International Energy and Environment Foundation (IEEF), Najaf, http://www.ijee.ieefoundation.org/, http://www.amrc.ieefoundation.org/, http://www.ieefoundation.org/

Contact: E-mail: muhanedl.alwaeli@uokufa.edu.iq, Mobile: +9647811185334

http://www.uokufa.edu.iq/faculty/staff_sites/en/index.php?muhanedl.alwaeli

https://www.scopus.com/authid/detail.uri?authorId=55385828500

https://scholar.google.com/citations?user=XIJJdesAAAAJ&hl=ar

References

K. E. Nilsen, “Numerical modelling of the aluminium extrusion process and comparison with results obtained from industrially extruded complex sections,” Ph.D. Thesis, Bournemouth University, 2014.

M. Kulczyk, S. Przybysz, J. Skiba, and W. Pachla, “Severe plastic deformation induced in Al, Al-Si, Ag and Cu by hydrostatic extrusion,” Arch. Metall. Mater., vol. 59, no. 1, pp. 59–64, 2014, doi: 10.2478/amm-2014-0010.

T. Bakhtiani, H. El-Mounayri, and J. Zhang, “Numerical simulation of aluminum extrusion using coated die,” Mater. Today Proc., vol. 1, no. 1, pp. 94–106, 2014, doi: 10.1016/j.matpr.2014.09.018.

J. D. Bressan, M. M. Martins, and S. T. Button, “Analysis of aluminium hot extrusion by finite volume method,” Mater. Today Proc., vol. 2, no. 10., pp. 4740-4747, 2015, doi: 10.1016/j.matpr.2015.10.007.

A. S. Chahare, and K. H. Inamdar, “Optimization of Aluminium Extrusion Process using Taguchi Method,” IOSR J. Mech. Civ. Eng., vol. 17, no. 01, pp. 61–65, 2017, doi: 10.9790/1684-17010016165.

S. Lou, G. Zhao, R. Wang, and X. Wu, “Modeling of aluminum alloy profile extrusion process using finite volume method,” J. Mater. Process. Technol., vol. 206, no. 1–3, pp. 481–490, 2008, doi: 10.1016/j.jmatprotec.2007.12.084.

A. Farjad Bastani, T. Aukrust, and S. Brandal, “Optimisation of flow balance and isothermal extrusion of aluminium using finite-element simulations,” J. Mater. Process. Technol., vol. 211, no. 4, pp. 650–667, 2011, doi: 10.1016/j.jmatprotec.2010.11.021.

Z. He, H. N. Wang, M. J. Wang, and G. Y. Li, “Simulation of extrusion process of complicated aluminium profile and die trial,” Trans. Nonferrous Met. Soc. China (English Ed., vol. 22, no. 7, pp. 1732–1737, 2012, doi: 10.1016/S1003-6326(11)61380-0.

M. Schikorra, L. Donati, L. Tomesani, and A. E. Tekkaya, “Extrusion Benchmark 2007 – Benchmark Experiments: Study on Material Flow Extrusion of a Flat Die,” Key Eng. Mater., vol. 367, pp. 1–8, 2008, doi: 10.4028/www.scientific.net/kem.367.1.

E. D. Schmitter, “Modelling massive forming processes with thermally coupled fluid dynamics,” Proc. COMSOL Multiphysics User’s Conf., no. 1, pp. 2–4, 2005.

D. B. Alfaro, E. Cueto, M. Doblare, and F. Chinesta, “Three-dimensional simulation of aluminium extrusion by the alpha-shape based natural element method,” Computer Methods in Applied Mechanics and Engineering, vol. 195, no. 33-36, pp. 4269-4286, 2006, doi: 10.1016/j.cma.2005.08.006.

R. A. Neama, M. A. R. S. Al-Baghdadi, and M. Al-Waily, “Effect of blank holder force and punch number on the forming behavior of conventional dies,” Int. J. Mech. Mechatronics Eng., vol. 18, no. 4, pp. 56–64, 2018.

M. Al-Waily, M. A. R. S. Al-Baghdadi, and R. H. Al-Khayat, “Flow velocity and crack angle effect on vibration and flow characterization for pipe induce vibration,” Int. J. Mech. Mechatronics Eng., vol. 17, no. 5, pp. 19–27, 2017.

R. H. Al-Khayat, M. A. R. S. Al-Baghdadi, R. A. Neama, and M. Al-Waily, “Optimization CFD study of erosion in 3D elbow during transportation of crude oil contaminated with sand particles,” Int. J. Eng. Technol., vol. 7, no. 3, pp. 1420–1428, 2018, doi: 10.14419/ijet.v7i3.14180.

M. A. R. Sadiq Al-Baghdadi, Z. M. H. Noor, A. Zeiny, A. Burns, and D. Wen, “CFD analysis of a nanofluid-based microchannel heat sink,” Therm. Sci. Eng. Prog., vol. 20, no. July, p. 100685, 2020, doi: 10.1016/j.tsep.2020.100685.

J. D. Bressan, M. M. Martins, and C. Bandini, “Validation of Finite Volume Method by hot extrusion analysis of aluminium alloy,” Mater. Today Proc., vol. 10, pp. 234–241, 2019, doi: 10.1016/j.matpr.2018.10.401.

K. P. V. Namburi, A. F. Kothasiri, and V. S. M. Yerubandi, “Modeling and simulation of Aluminum 1100 alloy in an extrusion process,” Mater. Today Proc., vol. 23, pp. 518–522, 2020, doi: 10.1016/j.matpr.2019.05.398.

A. Šupić, A. Bečirović, A. Obućina, and M. Zrilić, “Modeling and Simulation for Aluminium Profile Extrusion,” Procedia Struct. Integr., vol. 13, pp. 2077–2082, 2018, doi: 10.1016/j.prostr.2018.12.205.

F. Parvizian, T. Kayser, C. Hortig, and B. Svendsen, “Thermomechanical modeling and simulation of aluminum alloy behavior during extrusion and cooling,” J. Mater. Process. Technol., vol. 209, no. 2, pp. 876–883, 2009, doi: 10.1016/j.jmatprotec.2008.02.076.

H. Zhang, X. Li, X. Deng, A. P. Reynolds, and M. A. Sutton, “Numerical simulation of friction extrusion process,” J. Mater. Process. Technol., vol. 253, no. November, pp. 17–26, 2018, doi: 10.1016/j.jmatprotec.2017.10.053.

C. P. Kohar, A. Brahme, F. Hekmat, R. K. Mishra, and K. Inal, “A computational mechanics engineering framework for predicting the axial crush response of Aluminum extrusions,” Thin-Walled Struct., vol. 140, no. February, pp. 516–532, 2019, doi: 10.1016/j.tws.2019.02.007.

R. Comminal, M. P. Serdeczny, D. B. Pedersen, and J. Spangenberg, “Motion planning and numerical simulation of material deposition at corners in extrusion additive manufacturing,” Addit. Manuf., vol. 29, no. December 2018, p. 100753, 2019, doi: 10.1016/j.addma.2019.06.005.

A. Medvedev, A. Bevacqua, A. Molotnikov, R. Axe, and R. Lapovok, “Innovative aluminium extrusion: Increased productivity through simulation,” Procedia Manuf., vol. 50, pp. 469–474, 2020, doi: 10.1016/j.promfg.2020.08.085.

S. N. H. Mazlan, A. Z. Abdul Kadir, N. H. A. Ngadiman, and M. R. Alkahari, “Evaluation of geometrical benchmark artifacts containing multiple overhang lengths fabricated using material extrusion technique,” J. Mech. Eng. Sci., vol. 14, no. 3, pp. 7296–7308, 2020, doi: 10.15282/jmes.14.3.2020.28.0573.

Downloads

Published

2021-09-19 — Updated on 2021-09-19

Versions

How to Cite

[1]
M. A. R. S. Al-Baghdadi and M. Al-Waily, “Three-dimensional fluid-thermal-structure multiphysics interaction simulation model of aluminium extrusion process”, J. Mech. Eng. Sci., vol. 15, no. 3, pp. 8253–8261, Sep. 2021.

Issue

Vol. 15 No. 3 (2021): September 2021

Section

Article

License

Copyright (c) 2021 Universiti Malaysia Pahang Publishing

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

Similar Articles

<< < 35 36 37 38 39 40 41 42 43 44 > >> 

You may also start an advanced similarity search for this article.