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Updated: Jul 1, 2025
09:53
Predicting Catalyst Extrudate Breakage Based on the Modulus of Rupture
Published on: May 13, 2018
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New Method for Detecting Flange Fracture Initiation in Incremental Radial Extrusion.
1Faculty of Mechanical Engineering, Lublin University of Technology, 38 D Nadbystrzycka Str., 20-618 Lublin, Poland.
Materials (Basel, Switzerland)
|March 13, 2024
Summary
This study introduces a new method to predict flange fracture in incremental radial extrusion using finite element analysis (FEA). The method analyzes strain and fracture criteria to identify fracture initiation without extra material calibration experiments.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Mechanical Engineering
Background:
- Unconventional incremental radial extrusion utilizes constraining rings to enhance flange formation.
- This process yields flanges with constant thickness and larger diameters compared to standard extrusion.
- EN AW 6060 aluminum alloy is explored under cold forming conditions.
Purpose of the Study:
- To investigate flange fracture formation in incremental radial extrusion.
- To propose and validate a novel method for predicting material fracture initiation.
- To enable fracture prediction solely through finite element method (FEM) analysis.
Main Methods:
- Employing incremental radial extrusion with progressively increasing diameter rings.
- Utilizing EN AW 6060 aluminum alloy under cold forming conditions.
- Developing a new fracture prediction method based on strain, strain rate, and normalized Cockcroft-Latham fracture criterion.
Main Results:
- The proposed method accurately predicts fracture initiation using only FEM results.
- Differences in strain, strain rate, and fracture integral distributions correlate with fracture initiation.
- Eliminates the need for additional experiments for material calibration or limit parameter determination.
Conclusions:
- The novel FEM-based approach effectively predicts flange fracture in incremental radial extrusion.
- This method offers a significant advantage by avoiding material-specific experimental calibration.
- The findings contribute to optimizing the incremental radial extrusion process for aluminum alloys.
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