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Flexible Extrusion of 3-D Curved Profiles for Structural Components

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Flexible Extrusion of 3-D Curved Profiles for Structural Components

Dirk Becker, Marco Schikorra, and A. Erman Tekkaya, Institute of Forming Technology and Lightweight Construction (IUL)), University of Dortmund, Germany

Track: VALUE-ADDED PROCESSES - Metal Forming

ABSTRACT --- The extension of the common direct extrusion process to
curved profile extrusion (CPE) provides the possibility to manufacture 3-D
curved profiles in a very flexible way. In CPE, the exiting strand is deflected by
a guiding tool, so that the lateral offset induces a moment that causes a different
material flow in the die. In contrast to conventional bending methods, CPE has
no influence in terms of cross-section deformation, reduction of formability, or
residual stresses in the curved profile. Due to these advantages regarding
mechanical and geometrical properties and the reduction of the process chain,
production costs can be decreased significantly. The 3-D geometry of the
profile line eliminates the use of a plane surface to support the strand in the runout,
so that the challenge to manufacture profiles with the same accuracy as in a
conventional process is very high. Therefore, a flexible support for the
surmounting profile is necessary to prevent deformation, like bending or
twisting during this sensitive warm forming process. With the help of the Finite
Element Method (FEM), the influence of external forces on the material flow
will be analyzed.

© Extrusion Technology for Aluminum Profiles Foundation (ET Foundation). All rights reserved. No part of The Proceedings may be reproduced in any form without the express written permission of the ET Foundation.