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San Francisco's Golden Gate Bridge is exposed to temperatures ranging from -15 °C to 40 °C. At its coldest, the main span of the bridge is 1275 m long. Assuming that the bridge is made entirely of steel, what is the change in its length between these temperatures?
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Research on Energy Management in Forward Extrusion Processes Based on Experiment and Finite Element Method

Tomasz Miłek1, Olga Orynycz2, Jonas Matijošius3

  • 1Faculty of Mechatronics and Mechanical Engineering, Kielce University of Technology, Al. Tysiąclecia Państwa Polskiego 7, 25-314 Kielce, Poland.

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Summary
This summary is machine-generated.

Optimizing forward extrusion with sustainable methods, this study found conical and arc dies reduce energy use by 15% compared to flat dies. This improves efficiency and sustainability in metal forming processes.

Keywords:
decision-making in industrial processesenergy efficiency in manufacturingfinite element method in metal formingforward extrusion process optimizationpredictive modeling for process optimization

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Area of Science:

  • Materials Science and Engineering
  • Sustainable Manufacturing

Background:

  • Forward extrusion is a key metal forming process.
  • Energy efficiency and sustainability are critical concerns in industrial manufacturing.

Purpose of the Study:

  • To optimize the forward extrusion process for energy efficiency and sustainability.
  • To investigate the influence of die geometry and elongation coefficients on energy consumption.
  • To develop predictive models for process energy and extrusion force.

Main Methods:

  • Finite Element Method (FEM) simulations for analyzing material flow and deformation.
  • Experimental extrusion of lead profiles using flat, conical, and arc dies.
  • Artificial neural networks and regression analysis for energy prediction and force modeling.

Main Results:

  • Conical and arc dies demonstrated up to 15% energy savings over flat dies.
  • FEM simulations provided insights into deformation patterns, stress distribution, and energy losses.
  • Validated mathematical models accurately forecast peak extrusion force based on elongation parameters.

Conclusions:

  • Die geometry significantly impacts energy consumption and process efficiency in forward extrusion.
  • Sustainable methodologies, like using optimized die shapes, offer practical solutions for reducing energy use.
  • The findings enhance industrial efficiency and align with environmental sustainability goals.