Research on Energy Management in Forward Extrusion Processes Based on Experiment and Finite Element Method...

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.