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Analysis and simulation for shape control effects of square aluminum tube during ECAP

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Abstract

As an important engineering material, aluminum alloy profile is widely used in each department of national economy. With polyurethane mandrel in the hollow of the profiles, equal channel angular pressing (ECAP) can be used to refine mechanical properties of these hollow materials with good shape control effects. However, based on existing researches, the hollow profiles are only limited to circular ones. In this paper, a mechanical analysis of a square tube in ECAP with polyurethane mandrel is provided. Through the slab method in different deformation planes, the mechanical mechanism of shape control effects is found. The thicknesses can be maintained as its initial ones after ECAP. Both simulations and experiments are used to verify the calculated results by the analysis. After calculating, most errors between the final and initial thicknesses in both simulations and experiments are less than 10%.

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Abbreviations

t D :

Total channel thickness

dθ :

Pressing trip in a polar coordinate

Φ:

Inner corner in deformation zones

Ψ:

Outer corner in deformation zones

A1 and A2 :

Inner and outer parts of the alloy, respectively

R 1 :

Mandrel part of the polyurethane rubber

ta1 and ta2 :

Thicknesses of the square alloy in the deformation plane

tt − 1 and tt − 2 :

Thicknesses of the square alloy in the transverse plane

t r1 :

Thickness of the polyurethane rubber mandrel in the deformation plane

ri and ro :

Radii of inner and outer channel boundaries in deformation areas

r12 and r23 :

Radial radii of two boundaries between A1-R1 and R1-A2

ξ1 and ξ2 :

Deflection angles of the boundaries between A1-R1 and R1-A2

τ f :

Friction stress between the alloy and channel

τ mf :

Friction stress between the alloy and rubber

τ r :

Shear stress along the radial direction

σ :

Stress acting on the alloy from the channel

p :

Pressures on the alloy and rubber

p rubber :

Pressure on the surfaces between the alloy and rubber

k :

Shear yield stress of aluminum alloy

m alloy ‐ channel :

Friction factor of the surface between the alloy and channel

m alloy ‐ rubber :

Friction factor of the surface between the alloy and rubber

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Funding

This work is financially supported by the Doctor Start-Up Fund of Liaoning province (Grant No. 20180540098), the National Natural Science Foundation of China (Grant No. 71831002), the Program for Innovative Research Team in University of the Ministry of Education of China (Grant No. IRT_17R13), the Fundamental Research Funds for the Central Universities (Grant Nos. 3132019501, 3132019502), the National Natural Science Foundation of China (Grant Nos. 51504156, 51704067), the Outstanding Youth Fund of Jiangsu Province (Grant No. BK20180095), and the Prospective Applied Research from the Technological Innovation Project of Key Industry of Suzhou (Grant No. SYG201806).

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Authors and Affiliations

  1. Transportation Engineering College, Dalian Maritime University, 106026, Dalian, Liaoning, People’s Republic of China

    Wang Hongyu, Wei Jie, Teng Fei, Li Ting & Sun Juncai

  2. School of Mechanical Engineering and Automation, Northeastern University, 110819, Shenyang, Liaoning, People’s Republic of China

    Kong Xiangwei

  3. State Key Laboratory of Rolling & Automation, Northeastern University, 110819, Shenyang, Liaoning, People’s Republic of China

    Zhang Dianhua & Peng Wen

  4. Shagang School of Iron and Steel, Soochow University, 215021, Suzhou, Jiangsu, People’s Republic of China

    Zhang Shunhu

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  1. Wang Hongyu
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  2. Wei Jie
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Correspondence to Wang Hongyu.

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Hongyu, W., Jie, W., Fei, T. et al. Analysis and simulation for shape control effects of square aluminum tube during ECAP. Int J Adv Manuf Technol 108, 3859–3870 (2020). https://doi.org/10.1007/s00170-020-05489-2

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