Benchmark 2017 Modeling aluminum extrusion

S 20 by 24 June 2017 at the Congress Center of the Italian city of Verona PalaExpo jointly held the 10th Congress of Aluminum 2000 and the 6th Conference on aluminum extrusion Benchmark + 2017. These two events were so intertwined with each other, that it was impossible to understand, where else Congress, but where is the Conference. All four business days of the Congress and the Conference were filled with reports, Presentation and discussion, as well as a master class for anodizing and a visit to the neighboring METEF specialized exhibition of aluminum.

See. more According to the results of the Congress and the Conference + Benchmark 2017

Science and Technology of aluminum

Научно-техническая часть Конгресса и Конференции проходила параллельно в четырех конференц-залах и охватывала следующие темы:

  • aluminum products markets, development strategy, logistics
  • Anodizing of aluminum and staining
  • aluminum extrusion and "benchmark" of computer programs
  • The use of extruded aluminum
  • The ingots for extrusion of aluminum
  • Matrix and other tools for the extrusion of aluminum
  • Innovative technologies in aluminum extrusion
  • The microstructure of an extruded aluminum
  • for the production of extruded aluminum plant
  • Optimization of the aluminum extrusion process
  • aluminum forging
  • Casting and molding cast aluminum
  • Aluminum profiles for absorbing impact energy
  • Production and processing of the aluminum sheet for the automotive industry
  • Processing the aluminum surface
  • Cleaning aluminum enterprises drains
  • welding of aluminum

Benchmark-2017

Benchmark - competition of computer programs

One of the most interesting events of the Congress and the Conference was to present the results of the "benchmark" - "blind" testing the best software for simulation of extrusion process of aluminum and comparing the results of their calculations with the results of industrial experiment. The English word benchmark includes the concept of "testing", "Comparison with the standard" and has no direct counterpart in the Russian language. Therefore, for convenience, and we will call it "benchmark".

Such testing of computer programs for the simulation of aluminum extrusion - benchmarks - have been held several times. Their goal - to evaluate the possibilities of computer programs based on the finite element method in modeling real-world industrial aluminum extrusion experiments, and encourage them to develop and improve.

Pressing tools and profiles

Производилось моделирование экструзии алюминиевого сплава 6005А на матрице портхол с двумя зеркальными С-образными отверстиями для двух полых профилей (рисунок 1).

Figure 1 – Основные размеры профилей А и В в холодном состоянии [1, 2]

Главной задачей Бенчмарка-2017 являлось изучение изменения температуры матрицы и другого прессового инструмента в ходе экструзии (прессования) сложных полых профилей.

Комплект прессового инструмента состоял из семи частей (рисунок 2) [2]:

  • рассекатель/оправка (1),
  • матрица (2),
  • подкладка (3),
  • матричное кольцо (4),
  • больстер (5),
  • больстерное кольцо (6) и
  • суббольстер (7).

Figure 2 – Все «в сборе» для компьютерного моделирования:
aluminum billet, Profiles A and B, matrix ring splitter / mandrel, матрицей и подкладкой (1, 2, 3),
больстерное кольцо с больстером (5, 6) и суббольстер (7) [1]

Measurement temperature

To measure the temperature of the pressing tool applied 7 thermocouples, две из которых были установлены вблизи рабочих поясков матрицы обоих профилей (профиля А и профиля В), and the rest 4 – в различных местах матричного кольца (рисунок 3).

Figure 3 – Расположение термопар в матрице и матричном кольце [1]

Moreover, I worked noncontact thermometer at the outlet of the matrix. He was sent to the pattern A at a distance 630 mm from the outer end subbolstera.

technological conditions

  • Пресс: промышленный (SAPA), 30 МН (3000 тонн);
  • Внутренний диаметр контейнера: 210 mm;
  • Длина контейнера: 1055 mm;
  • Диаметр заготовки: 203 mm;
  • Длина заготовки: 810 mm;
  • Скорость пресс-штемпеля: 9,86 мм/с;
  • Рабочий ход пресс-штемпеля: 792 мм (810 мм длины заготовки минус 18 мм длины пресс-остатка);
  • Тянущее усилие пуллера (два профиля одновременно): 110 кг (1100 Н);
  • first 4 blank - with 1 by 4: для стабилизации температуры прессового инструмента;
  • 4 blank - with 5 by 8: промышленные эксперименты с охлаждением профилей воздухом (1 ºС/с);
  • 4 blank - with 9 by 12: промышленные эксперименты с охлаждением профилей водой (100 ºС/с);

initial temperature

  • Температура пресс-шайбы: 350 ºS;
  • Температура контейнера: 410 ºS;
  • Температура заготовки: 465 ° C front end, 360 ºС задний торец (перепад 105 ºС по длине заготовки);
  • Температура матрицы: в печи – 480 oC, cooling to 451-470 ° C during loading in the press.

Materials

  • Алюминиевый сплав: 6005А-О;
  • Материал матрицы и другого прессового инструмента: сталь AISI H-11, 45-47 HRC.

Presentation of results

Результаты моделирования экструзии всех участников бенчмарка-2017 были представлены в следующем виде:

  • Rated pressing force
  • Both temperature profiles at the exit of the matrix
  • velocity profiles output from the matrix
  • The temperature of the matrix in predetermined points of the seven
  • Deviations languages ​​matrix in the direction of extrusion
  • Location of longitudinal welds in the profiles
  • The grain size of the microstructure of profiles with air cooling
  • The grain size of the microstructure with a water-cooling profiles
  • The length of the traces of "old" blank from a place to stop the press when changing the workpiece
  • The curvature profiles with respect to the nominal shape.

Results industrial experiment

Некоторые интересные результаты промышленного эксперимента:

  • Градиентный нагрев заготовки обеспечивает изотермическое прессование профилей: постоянную скорость 24 m / min at the output of the matrix and a constant temperature of about 580 ºС (рисунки 4 and 5)
  • The temperature at the running web matrix is ​​constant and is about 575 ºС (рисунок 6)
  • The temperature of the matrix near the matrix ring is about 360-380 ºС (рисунок 6)

Figure 4 - Velocity profiles A and B output from the matrix

Figure 5 - Temperature profiles A and B output from the matrix

Figure 6 – Температура матрицы вблизи поясков (Т1 и Т2) и
вблизи матричного кольца (Т3-Т6)

  • Maximum deviation languages ​​matrix during extrusion is about 0,5 мм (по результатам моделирования).

Benchmark actor-2017

The benchmark 2017 attended 6 computer programs of different companies from different countries.

See. more Program of the Congress and the Conference + Benchmark 2017 (Room Verdi, 20-21 June 2017).

It was nice to find, that one of the participants in this benchmark is a computer program QFORM VX Company QuantorForm Ltd, главные офисы которой находятся в Москве (Россия) и Оксфорде (Великобритания). QuantorForm Ltd is one of the world leaders in the design and implementation of computer simulation of metal processing pressure.

Friendship won

Results of the "blind" the simulation of six participants in this contest, industrial as well as results of the experiment, It was presented at a general overview of all the participants of the Congress and the Conference of. Moreover, All participants of the benchmark will report on the results of their calculations.

Without going into details, note, that the results of the calculations are very similar to the results of industrial experiment.

A feature of this benchmark, as well as all previous, was that, that due to the complexity of the problem to be solved, He was not considered an official competition, tournament or championship companies-software developers. in front of, This event is a unique opportunity - a friendly and benevolent – clarify some points in the practice of the aluminum extrusion modeling for each participant. Therefore, the winner of this "race" is not officially declared.

Sources:

  1. ICEB2017-Benchmark Settings – Donati L., A. Prawns, B. Reggiani, L. Tomesani - University of Bologna - 10thAluminium Two Thousand World Congress – 6th ICEB International Conference, 2017.
  2. BENCHMARK EXPERIMENTAL RESULTS – Donati L., A. Prawns, B. Reggiani, L. Tomesani University of Bologna10th Aluminium Two Thousand World Congress – 6th ICEB International Conference, 2017.