Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method
Shear assisted processing and extrusion (ShAPE) is a solid-phase processing technique that adds an additional shear force as compared with a conventional extrusion approach. Recently, ShAPE has demonstrated the capability of extruding high-performance aluminum alloy 7075 (AA7075) tubes at speeds up...
| Main Authors: | , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2022-09-01
|
| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127522006323 |
| _version_ | 1818496271888941056 |
|---|---|
| author | Lei Li Md Reza-E-Rabby Nicole Overman Tianhao Wang Scott Whalen Glenn Grant Suveen Mathaudhu Ayoub Soulami |
| author_facet | Lei Li Md Reza-E-Rabby Nicole Overman Tianhao Wang Scott Whalen Glenn Grant Suveen Mathaudhu Ayoub Soulami |
| author_sort | Lei Li |
| collection | DOAJ |
| description | Shear assisted processing and extrusion (ShAPE) is a solid-phase processing technique that adds an additional shear force as compared with a conventional extrusion approach. Recently, ShAPE has demonstrated the capability of extruding high-performance aluminum alloy 7075 (AA7075) tubes at speeds up to 12.2 m/min without surface tearing. However, the relationship among the ShAPE processing parameters, thermomechanical conditions, contact conditions, heat generation, and microstructure evolution remains primarily empirical because an insightful understanding of the associated physics is still lacking. To help elucidate these relationships, this work proposes a thermomechanical meshfree model for the first time for ShAPE processing of AA7075 using the smoothed particle hydrodynamics (SPH) method. The meshfree model is first validated thoroughly by experimental data in terms of material flow, die face temperature, and extrusion force with various processing parameters. The validated model is then used to analyze the steady-state contact conditions and heat generation rates during ShAPE processing. Distributions of the average grain size of AA7075 being extruded are calculated using the SPH model output. The meshfree model results reveal that extrusions conducted at lower temperatures and higher strain rates yield more refined grains and possibly higher material strength, which is also consistent with the experimental observations. |
| first_indexed | 2024-12-10T18:31:17Z |
| format | Article |
| id | doaj.art-447e61c40ef44aa5b3efe0f97edad33c |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-12-10T18:31:17Z |
| publishDate | 2022-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-447e61c40ef44aa5b3efe0f97edad33c2022-12-22T01:37:55ZengElsevierMaterials & Design0264-12752022-09-01221111010Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics methodLei Li0Md Reza-E-Rabby1Nicole Overman2Tianhao Wang3Scott Whalen4Glenn Grant5Suveen Mathaudhu6Ayoub Soulami7Physical and Computational Sciences Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA 99354, USA; Corresponding authors.Energy and Environment Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA 99354, USAEnergy and Environment Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA 99354, USAEnergy and Environment Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA 99354, USAEnergy and Environment Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA 99354, USAEnergy and Environment Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA 99354, USAMetallurgical and Materials Engineering, Colorado School of Mines, 920 15th St., Golden, CO 80401, USAEnergy and Environment Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA 99354, USA; Corresponding authors.Shear assisted processing and extrusion (ShAPE) is a solid-phase processing technique that adds an additional shear force as compared with a conventional extrusion approach. Recently, ShAPE has demonstrated the capability of extruding high-performance aluminum alloy 7075 (AA7075) tubes at speeds up to 12.2 m/min without surface tearing. However, the relationship among the ShAPE processing parameters, thermomechanical conditions, contact conditions, heat generation, and microstructure evolution remains primarily empirical because an insightful understanding of the associated physics is still lacking. To help elucidate these relationships, this work proposes a thermomechanical meshfree model for the first time for ShAPE processing of AA7075 using the smoothed particle hydrodynamics (SPH) method. The meshfree model is first validated thoroughly by experimental data in terms of material flow, die face temperature, and extrusion force with various processing parameters. The validated model is then used to analyze the steady-state contact conditions and heat generation rates during ShAPE processing. Distributions of the average grain size of AA7075 being extruded are calculated using the SPH model output. The meshfree model results reveal that extrusions conducted at lower temperatures and higher strain rates yield more refined grains and possibly higher material strength, which is also consistent with the experimental observations.http://www.sciencedirect.com/science/article/pii/S0264127522006323Shear assisted processing and extrusion (ShAPE)Smoothed particle hydrodynamicsAluminum alloy 7075Stick-slip contact conditionHeat generation rate |
| spellingShingle | Lei Li Md Reza-E-Rabby Nicole Overman Tianhao Wang Scott Whalen Glenn Grant Suveen Mathaudhu Ayoub Soulami Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method Materials & Design Shear assisted processing and extrusion (ShAPE) Smoothed particle hydrodynamics Aluminum alloy 7075 Stick-slip contact condition Heat generation rate |
| title | Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method |
| title_full | Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method |
| title_fullStr | Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method |
| title_full_unstemmed | Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method |
| title_short | Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method |
| title_sort | analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method |
| topic | Shear assisted processing and extrusion (ShAPE) Smoothed particle hydrodynamics Aluminum alloy 7075 Stick-slip contact condition Heat generation rate |
| url | http://www.sciencedirect.com/science/article/pii/S0264127522006323 |
| work_keys_str_mv | AT leili analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod AT mdrezaerabby analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod AT nicoleoverman analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod AT tianhaowang analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod AT scottwhalen analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod AT glenngrant analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod AT suveenmathaudhu analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod AT ayoubsoulami analysisofcontactconditionsandmicrostructureevolutioninshearassistedprocessingandextrusionusingsmoothedparticlehydrodynamicsmethod |