Axisymmetric deviation influence on structural and mechanical characteristics of some copper semifinished products.
Ghiban, Nicolae ; Serban, Nicolae ; Ghiban, Alexandru 等
1. INTRODUCTION
Nowadays, the equilibrium of flowing speeds and the control of the
deformation nonuniformity in order to obtain quality products, in the
case of extrusion process of the non-rounded products, there are matters
of experience. The projecting and the technological practice activities
are still made in an empirical way, using the results obtained from the
experience of some manufacturers, and also the ones that are obtained
from industrial tests, using the "step by step" technique,
(Altan et al., 1994).
The projecting of the die, in the case of extrusion process of the
non-rounded products, is not only an operation of placing the die cavity
(porthole) inside the block, (Ulysse, 2002), but also an operation of
establishment of the geometrical and technological parameters
correlation which determinates the materials flow dynamics in the
analyzed case study, (Zienkiewicz & Taylor, 2000), (Hartley et al.,
1992).
The purpose of this paper is to show, by different methods,
experimental as well as theoretical, the problems still not fully solved
in the matter of extrusion of the non-rounded products. Also, the
authors tried to establish some correlations between technological
parameters by which one can operate in a practical, easy and efficient
way, in comparison with other researchers (Altan et al., 1994), (Ulysse,
2002).
2. MATERIALS AND RESEARCH METHOD
The experimental researches were made with a hydraulic press of
1000 tones force, which is usually used for the extrusion of brass,
bronze, copper and copper--chromium bars, and which possesses an
horizontal design and can work with two or more profiles simultaneously.
For the extrusion of the analysed profiles, the following billet
dimensions were used: for brass [PHI] 174 x 400 mm, and for copper [PHI]
145 x 300 mm. For the billets extrusion, the tools were heated at a
temperature of 250-280[degrees]C, and after the end of the extrusion
process their cooling was made slowly for avoiding material cracking.
The billets heating was made in an induction furnace of low frequency,
as follows: the brass billet was heated at 850[degrees]C and the copper
billet at 950[degrees]C.
[FIGURE 1 OMITTED]
From the non-rounded extruded profiles (figure 1, a and b) there
were made samples for mechanical tests at environmental temperature,
(Ghiban, 1997).
The mechanical tests were made using a sensitivity of 1%. The yield
strength was measured using an extensometer on the samples, with an
accuracy of the measurement of 0.01%. The tensile strength, the yield
strength and the elongation were measured.
Metallographic analysis was made using an Reichert microscope at
magnifying powers of 500-2000 times, in the section of the extruded
samples, using an ammonium persulphate solution for the metallographic
attack.
3. RESULTS AND INTERPRETATION
In order to highlight the influence of incorrect positioning of the
die cavity (deviation) on the structure and on the mechanical properties
of the extruded products, there were made experimental researches with
three positions of the die cavity for each profile, as follows: for the
brass profile, there were made experiments with the deviations [y.sub.1]
= -30 mm (non-optimum position), [y.sub.2] = 0 (optimum position) and
[y.sub.3] = +10 mm (non-optimum position of the die cavity); and for the
copper profile, with the deviations [y.sub.1] = -40 mm (non-optimum
position), [y.sub.2] = 0 (optimum position) and [y.sub.3] = +30 mm (also
a non-optimum position of the die cavity), (Ghiban, 1997), (COSMOS,
documentation, 1997).
The samples cuted from each profile were utilized in order to
highlight the microstructural transformations which depend on the
extrusion conditions. As can be seen from figure 2, the brass samples
have a dual phase structure, made of a mixture of [alpha] solid solution
(Zn in Cu solid solution, with a FCC lattice) and [beta]' solid
solution (a solid solution based on the electronic compound CuZn, with
an electronic density of 3/2, and with a BCC lattice). The dual phase
structure of brass is highly influenced by the extrusion conditions: in
the case of an optimum position of the die cavity (no deviation, figure
2, a), it can be seen an homogeneous distribution of the two solid
solutions; as the deviation grows, a nonuniform distribution of the two
phases is observed, and even a Widmannstatten structure in some areas
(figure 2, b).
[FIGURE 2 OMITTED]
The copper samples have a monophase structure, with a FCC lattice,
mackled with distinct color shades grains, figure 3, a and b. The
monophase structure of the copper samples (oxidized) is also highly
influenced by the extrusion conditions; the medium conventional diameter
of the grain being dependent of the values for the deviations from
linearity and coaxiallity (misalignment); while for the samples without
deviation, the medium conventional diameter is 0.0315 mm, at a deviation
of y = +30 mm the diameter is 0.0287 mm, and for y = -40 mm the
inhomogeneous granulation generated an medium conventional diameter of
0.0268 mm.
[FIGURE 3 OMITTED]
The variation of mechanical characteristics during extrusion with
different values of deviation is suggestively given in the figure 4 (a,
b, c for the brass samples) and figure 5 (a, b, c for the copper
samples).
[FIGURE 4 OMITTED]
[FIGURE 5 OMITTED]
4. CONCLUSIONS
The microstructural analysis showed the dependence of structural
modifications on the extrusion conditions. In the case of brass samples,
the dual phase structure of brass is described by a uniform distribution
of the two solid solutions (when the deviation is zero) and by a
nonuniform distribution of the phases, with an Widmannstatten aspect
(for both samples with deviation). In the case of copper samples, the
structure is homogeneous (with the medium conventional diameter of
0.0315 mm when the deviation is zero) and inhomogeneous (with the medium
conventional diameter of 0.0268 mm when the deviation is y = -40 mm,
respectively with the medium conventional diameter of 0.0287 mm when the
deviation is y = +30 mm).
The analysis of mechanical characteristics values showed that a
correlation may be described between linear deviation--coaxiallity and
the mechanical characteristics of the semifinished products; when the
linear deviation grows it also grows the tensile strength and the
hardness, but the plasticity decreases in value. In the case of brass
samples is trot out a growth of the tensile strength and hardness values
of approximately 5% and a decrease of elongation of approximately 5.5%
for a deviation y = +10 mm and a growth of the same characteristics with
approximately 10% when the deviation is y = -30 mm. In the case of
copper samples, the mechanical characteristics modification is 12-14%
when the deviation is y = -40 mm, and approximately 10-11% when the
deviation is y = +30 mm.
5. REFERENCES
Altan, T.; Oh, S. & Gegel, H. (1994). Metal
Forming--Fundamentals and Applications, ASM, 1994
COSMOS M 1.65 (1997). Documentation
Ghiban, N. (1997). Studies and experimental researches about the
non-rounded extruded profiles, Doctoral Thesis, University Politehnica
Bucharest
Hartley, P.; Pillinger, I. & Sturgess, C.E.N. (1992). Numerical
Modelling of Material Deformation Processes, Springer--Verlag
Ulysse, P. (2002). Extrusion die design for flow balance using FE
and optimization methods. International Journal of Mechanical Sciences,
Vol. 44 (2002), pp 319-341
Zienkiewicz, O.C. & Taylor, R.L. (2000). Finite Element Method,
Elsevier Butterworth-Heinemann, ISBN 0-7506-5049-4