Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices
The results obtained experimentally with the use of Hopkinson bar and numerical results on backward extrusion of 1050A aluminum at 10 m/s tool speed are presented, in order to assess the extrusion technology applied in the design of energy-absorbing devices. The devices of this type should satisfy t...
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Інститут проблем міцності ім. Г.С. Писаренко НАН України
2016
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| Цитувати: | Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices / G. Ryzińska, R. Gieleta // Проблемы прочности. — 2016. — № 4. — С. 93-103. — Бібліогр.: 15 назв. — англ. |
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irk-123456789-1735102020-12-08T01:27:00Z Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices Ryzińska, G. Gieleta, R. Научно-технический раздел The results obtained experimentally with the use of Hopkinson bar and numerical results on backward extrusion of 1050A aluminum at 10 m/s tool speed are presented, in order to assess the extrusion technology applied in the design of energy-absorbing devices. The devices of this type should satisfy the requirements, particularly, constant force versus displacement of the piston and the amount of the energy absorbed by the object. Numerical analyses of three variants of the absorbing device geometry were presented. The obtained results allowed an appropriate selection of geometric parameters of the device, and, as a result, the requirement of the proper amount of absorbed energy was satisfied. 2016 Article Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices / G. Ryzińska, R. Gieleta // Проблемы прочности. — 2016. — № 4. — С. 93-103. — Бібліогр.: 15 назв. — англ. 0556-171X http://dspace.nbuv.gov.ua/handle/123456789/173510 539.4 en Проблемы прочности Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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Научно-технический раздел Научно-технический раздел |
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Научно-технический раздел Научно-технический раздел Ryzińska, G. Gieleta, R. Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices Проблемы прочности |
| description |
The results obtained experimentally with the use of Hopkinson bar and numerical results on backward extrusion of 1050A aluminum at 10 m/s tool speed are presented, in order to assess the extrusion technology applied in the design of energy-absorbing devices. The devices of this type should satisfy the requirements, particularly, constant force versus displacement of the piston and the amount of the energy absorbed by the object. Numerical analyses of three variants of the absorbing device geometry were presented. The obtained results allowed an appropriate selection of geometric parameters of the device, and, as a result, the requirement of the proper amount of absorbed energy was satisfied. |
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Ryzińska, G. Gieleta, R. |
| author_facet |
Ryzińska, G. Gieleta, R. |
| author_sort |
Ryzińska, G. |
| title |
Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices |
| title_short |
Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices |
| title_full |
Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices |
| title_fullStr |
Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices |
| title_full_unstemmed |
Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices |
| title_sort |
experimental and numerical modeling of the extrusion process in 1050a aluminum alloy for design of impact energy-absorbing devices |
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Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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2016 |
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Научно-технический раздел |
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http://dspace.nbuv.gov.ua/handle/123456789/173510 |
| citation_txt |
Experimental and Numerical Modeling of the Extrusion Process in 1050A Aluminum Alloy for Design of Impact Energy-Absorbing Devices / G. Ryzińska, R. Gieleta // Проблемы прочности. — 2016. — № 4. — С. 93-103. — Бібліогр.: 15 назв. — англ. |
| series |
Проблемы прочности |
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2025-07-15T10:15:15Z |
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| fulltext |
UDC 539.4
Experimental and Numerical Modeling of the Extrusion Process in 1050A
Aluminum Alloy for Design of Impact Energy-Absorbing Devices
G. Ryziñska
a
and R. Gieleta
b
a Rzeszów University of Technology, Rzeszów, Poland
b Military University of Technology, Warsaw, Poland
The results obtained experimentally with the use of Hopkinson bar and numerical results on
backward extrusion of 1050A aluminum at 10 m/s tool speed are presented, in order to assess the
extrusion technology applied in the design of energy-absorbing devices. The devices of this type
should satisfy the requirements, particularly, constant force versus displacement of the piston and the
amount of the energy absorbed by the object. Numerical analyses of three variants of the absorbing
device geometry were presented. The obtained results allowed an appropriate selection of geometric
parameters of the device, and, as a result, the requirement of the proper amount of absorbed energy
was satisfied.
Keywords: extrusion, 1050A aluminum alloy, finite element method (FEM), Hopkinson
bar.
Introduction. The increasing competition and intensification of production in the
engineering industry make it necessary to introduce new materials with desired properties,
as well as to search for new unconventional applications of previously known technologies
of metal forming, e.g., extrusion. One of such innovations is an attempt to apply the
elements of extrusion technology in the design of devices absorbing the impact energy.
When designing this type of solutions, the detailed information on the behavior of a
metallic material applied in the range of high-speed deformations up to 5000 s�1 is
necessary. There are mathematical models pertmitting description of the behavior of
material subjected to deformation with a very high speed. However, noteworthy is that
these models require the determination of a number of constants and coefficients for each
material [1–3]. The alternative solution is to use the data on the material behavior material
in the range of high-speed deformations obtained by using the advanced research
equipment. The most commonly used method for determining material properties at high
strain rates is the split-Hopkinson pressure test [4–9]. There is also a method with use of a
rotary hammer, which allows stretching and bending of the specimens with linear velocity
ranged from 5 to 40 m/s, which is equal to strain rate ranged from 102 to 104 s�1 [10]. The
critical issue of the research on dynamic deformation, also conducted on flywheel
machines, is the course and the interpretation of the achieved performance graph. There are
many doubts as to the correctness of the analysis of the results, especially at the starting
phase of deformation. Whether the observed varied performance graphs are caused by the
specific design and work of the dynamic deformation of the research device, the structure
of the gripper/handle, the specimen shape and the ability to identify and tune-off/filter the
interferences [11, 12].
In this paper, the test results obtained with an application of the Hopkinson bar and
numerical calculation results of backward extrusion process of 1050A aluminum grade at a
speed of 10 m/s are presented. The elements of extrusion technology have been used in the
process of designing of the impact energy absorbing device.
Currently used technology of the controlled acquisition and absorption of impact
energy consists mainly of two types: crash technology and technology of springs. The crash
technology, innovative and patented by Axtone company, is based upon a permanent plastic
© G. RYZIÑSKA, R. GIELETA, 2016
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4 93
deformation of metal filament sheared from the outer surface of the bumper body
(including peeling and folding technology). Upon the collision, the outer surface of the
bumper is machined by the cutting blades. The level of absorbed energy depends on the
size and the cross section of the cutting tape, which makes possible a rather wide range of
control parameters of the device, depending on the needs of the particular application. The
crash bumpers, currently produced in accordance with the applicable standards, guarantee a
controlled acquisition of large amounts of energy emerging as a result of a collision, in case
of emergency situations. Energy absorption capacity of a bumper often reaches 1300 kJ.
For comparison, the currently used standard bumper can absorb about 70 kJ [13]. The key
aspect of all safety systems is their reliability. This applies to all bumpers, whose efficiency
must be confirmed by a number of full-scale tests. Crash technology is based on a
controlled takeover and absorption of a very high energy under the conditions of the
accident taking place at high speeds. To ensure the maximum flexibility of the proposed
solutions, the individual solutions, in accordance with the diverse needs of customers, are
currently being designed based on the patented cutting technology . In view of the
increasing competition, there is a search for new solutions in this field, which can expand
the range of products offered and introduce a better performance of these products. This
concerns the quantity of energy absorption, stability or strength during operation. The
devices for absorbing impact energy must meet certain requirements, such as the amount of
energy absorbed, a stable force level during an operation, a certain value of force, etc.
When analyzing the requirements for such devices, it is noteworthy that, in the case of a
test of an application of extrusion technology, the condition of a constant force can be met
by the backward extrusion technology.
A very important issue is the choice of the charge material, which, while deforming,
allows one to absorb the stored energy. Due to the low propensity to strengthening and low
weight, the aluminum alloys have been taken into account (Table 1), from which the
available 1050A aluminum alloy has been chosen.
Material Test. In order to obtain data on the material behavior for a wide range of
strain rate, the static compression tests and dynamic tests using the Hopkinson bar have
been performed. Static compression tests of aluminum alloy have been carried out on the
Instron 8862 testing machine. The test specimens in the form of cylinders of dimensions
D� 10 mm and L� 7.5 mm have been prepared by turning (Fig. 1).
Compression tests have been carried out with controlling of the displacement motion of
the jaws at a rate of 5 mm/min. For an accurate measurement of specimen contraction/
shortening, the Instron extensometer attached directly to the compression pads has been
used. The static compression test procedure is illustrated by Fig. 2.
G. Ryziñska and R. Gieleta
94 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
T a b l e 1
Properties of the Selected Low Strain Hardening Materials [14]
PN EN 573-3 Chemical
composition (%)
R0 2. ,
MPa
Rm ,
MPa
1080A 99.8Al 15–105 60–150
1070A 99.7Al 15–105 60–150
1050A 99.5Al 20–130 65–160
1200 99.0Al 25–140 75–170
1100 99.0Al 105 110
In the static compression tests, the relations of stresses and strains have been
determined. Overall figures obtained in tests of static compression of the aluminum alloy
have been presented in Fig. 3. The graph shows the engineering stresses and strains. The
shapes of specimens after the tests are also shown in Fig. 3.
Compression tests at high strain rate have been carried out in a specialized test bench
with a system of elastic rods (modified Hopkinson bar or the Kolsky bar). A striker bar of
specified length produces an adequate loading duration. The impact of the striker bar triggers
An Application of the Extrusion Process for the Design ...
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4 95
Fig. 1. 1050A aluminum alloy specimens before compression test.
Fig. 2. Static compression tests of 1050A aluminum alloy.
Fig. 3. Collective graph of 1050A aluminum alloy static compression test and shapes of specimens
after static compression test.
the automatic data registration from the strain gauges located on both the incident and
transmission bars. Stress, strain, and strain rate are then calculated from the data collected
via the strain gauges. A general schematic representation of the equipment is shown in
Fig. 4. For the signal amplification from the measuring rods (electroresistant deformeter)
and the signal acquisition from the bench (the signals from the laser barriers for measuring
the projectile velocity) the fast processes amplifier LTT500 by Tasler (LTT Labortechnik
GmbH Tasler, Germany), the measuring card NI USB-6366 by National Instruments and
the originally developed specialized software have been applied. In the described bench,
the amplifier and the A/D measuring card have a bandwidth equal to 1 MHz. During the
test the signals have been sampled at the time interval of 0.5 �s.
A typical specimen inserted between measuring bars is depicted in Fig. 5, while
samples of waveforms of the measuring rods are shown in Figs. 6 and 7.
96 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
Fig. 4. A perspective view of the SHPB apparatus for testing materials at high strain rates (SHPB =
split-Hopkinson pressure bar).
Fig. 5. Specimen between the measuring bars.
Fig. 6. Exemplary signals from the measuring bars.
G. Ryziñska and R. Gieleta
On the basis of the registered signals from the measuring rods, the calculations of
strains, stresses and strain rates in a specimen have been performed according to the
following relationships for the elastic rods:
� �( ) ( ) ,t
C
L
t dtR
t
�� �2 0
0
(1)
� �( ) ( ),t
ES
S
t
p
pr
T�
0
(2)
� ( ) ( ),� �t
C
L
tR��2 0
(3)
where C0 is wave propagation velocity, L is length of the specimen, E is the Young
modulus of measuring bars, S p0 and S pr are cross-sectional areas of bar and specimen,
respectively, �R t( ) and �T t( ) are signals in time for the reflected wave and the wave in
transmitted bar, respectively.
The calculated values of �( )t and �( )t were used to construct plot of the stresses
and strains for the given strain rate.
The overall graphs obtained in the compression tests at high strain rates are shown in
Figs. 8–10. Figure 11 shows an example of the specimens after the dynamic tests.
Comparing the relationship between stresses and strains for different strain rates, it can
be seen that the tested 1050A aluminum alloy shows a small sensitivity to the strain rate.
The maximum stress at a strain of 0.3 for the specimen type D10/L5 is equal to 180 MPa,
for the specimen type D10/L3 at the same deformation is 220 MPa, and for the specimen
type D10/L1 is 270 MPa.
The data obtained from the static compression tests and from the tests with an
application of the Hopkinson bar have been applied for simulation of the material behavior
in the backward extrusion process at high speed.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4 97
Fig. 7. Signals from measuring bars processed for calculations of stresses and strains.
An Application of the Extrusion Process for the Design ...
FEM Modeling. In the calculations of the impact energy absorption device, the
SimufactForming software has been used [15]. The geometry of the model has been set as
axisymmetric. It has been assumed that the deformable aluminum alloy charge closed in a
rigid container gets into a contact with a rigid punch. Application of the feedstock in the
form of a sleeve ensures that the total deformable material remains in the container (Fig. 12c).
Motion of the punch has been forced by a single stroke with a suitably chosen large initial
mass (20 ton) of the linear speed of 10 m/s. The dimensions of the aluminum alloy charge,
in all cases, have been established, and in the case of the punch three different variants of
outer diameter (d1 100� mm, d2 102� mm, and d3 104� mm) have been applied (Fig. 12).
In numerical calculations, elements of Quad 10 type of 0.5 mm size were used. A detailed
description of the FEM model is given in Table 2.
98 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
Fig. 8. Collective graph of 1050A aluminum alloy (compression test at high strain rates) D10/L5.
Fig. 9. Collective graph of 1050A aluminum alloy (compression test at high strain rates) D10/L3.
G. Ryziñska and R. Gieleta
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4 99
Fig. 10. Collective graph of 1050A aluminum (compression test at high strain rates) D10/L1.
a b
Fig. 11. Exemplary specimens of 1050A aluminum after dynamic compression test at high strain
rates: (a) D �10 mm, L � 5 mm; (b) D �10 mm, L �1 mm.
b
Fig. 12. Geometrical parameters of the impact energy-absorbing device: (a) punch; (b) ingot; (c)
general view (e – punch, f – ingot, g – container).
a
c
An Application of the Extrusion Process for the Design ...
Based on the calculations, the graphs of the relations of the force from the punch
displacement for three cases of the punch geometry have been constructed. Depending on
the dimensions, three different values of the maximum force have been obtained (Fig. 13).
The varied size of the resulting force depending on the geometry of the applied punch
is related to the time, in which the impact energy is absorbed, and the time of deceleration
in the tool from 10 to 0 m/s (Figs. 14 and 15). Exemplary results of FEM calculations
(effective plastic strain and effective stress in ingot) are shown in Fig. 16.
The relations obtained with an application of three different geometric configurations
of the punch make it possible to assess the extent, to which the device is able to absorb the
necessary amount of energy by the controlled deformation of the 1050A aluminum. This is
due to the time required to slow down the motion of the punch. The calculation results
show that the use of an external diameter of the punch of 104 mm can meet the requirement
100 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
T a b l e 2
Selected Features of the Applied FEM Model
Feature Description
Type of geometry Axisymmetric
Approach Updated Lagrangian
Friction Bilinear (Coulomb 0.05 and Tresca 0.08)
Temperature 293 K
Initial velocity 10 m/s
Mass of hammer 20 ton
Expected value of absorbed energy 1 MJ
Expected force 2000 kN
Number of elements 2384
Type of element Quad 10
Remeshing Yes
Integration procedure Explicit
Yield criterion Huber–Mises
Flow rule Prandtl–Reuss
Fig. 13. The relationship between force and displacement for the examined geometric variants of
punch (1050A aluminum).
G. Ryziñska and R. Gieleta
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4 101
Fig. 14. Dependence between time and punch velocity for various geometric punch configurations
(1050A aluminum).
Fig. 15. Dependence between time and absorbed energy for various geometric punch configurations
(1050A aluminum).
a b
Fig. 16. Exemplary results of FEM calculations: (a) effective plastic strain – ingot 102-70-500;
(b) effective stress – ingot 102-70-500.
An Application of the Extrusion Process for the Design ...
to absorb 1 MJ of energy in the shortest possible time. In the transport industries, there is a
need for devices absorbing different preset amounts of the impact energy, which vary with
the particular vehicle wight. That is why an ability to change parameters of operation of
such a device is very important and it can be achieved by variation of the punch geometry.
At the next phase, it is planned to test the prototype of the designed device.
Conclusions. In this paper, the results of experimental research performed with an
application of the Hopkinson bar and of numerical calculations of backward extrusion
process of 1050A aluminum at a speed of 10 m/s have been presented. Extrusion
technology have been used in designing of the impact energy absorbing device. The
analysis of results obtained made it possible to draw the following conclusions:
1. The research performed confirmed a possibility to use the extrusion technology in
the design of the impact energy-absorbing devices.
2. On the basis of calculations it can be stated that the process of backward 1050A
aluminum extrusion can be used in the construction of the impact energy-absorbing
devices, while detailed results of the calculations should be confirmed experimentally.
3. Calculations have shown that the use of geometrical parameters of punch
100-70-500 makes it possible to completely absorb 1 MJ of impact energy during the time
of 0.072 s. Increase in the punch cross-sectional area results in shortening the time required
to absorb the impact energy and to increase the force.
4. The solution satisfies the industrial requirements of the constant force, while the
ability to absorb a certain amount of energy turned out to be higher than in the existing
solutions, which can be used, in particular, in rail vehicles with a high weight. Application
of the feedstock in the form of a sleeve allows one to keep the total deformable material in
the container, in contrast to the existing crash bumper solutions.
5. A significant advantage of this solution is a possibility of continuous adjustment of
the force, as well as of the amount of energy absorbed, depending on the weight of the
vehicle, by a suitable choice of the device geometry, which it is advantageous for industrial
production. The developed impact energy-absorbing device may widen the scope of
manufacturers of this type of equipment on the market.
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102 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
G. Ryziñska and R. Gieleta
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15. Simufact.Forming v.13.2.
Received 10. 08. 2016
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4 103
An Application of the Extrusion Process for the Design ...
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/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
/ErrorControl /WarnAndContinue
/FlattenerIgnoreSpreadOverrides false
/IncludeGuidesGrids false
/IncludeNonPrinting false
/IncludeSlug false
/Namespace [
(Adobe)
(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
/AddColorBars false
/AddCropMarks false
/AddPageInfo false
/AddRegMarks false
/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
/DestinationProfileSelector /DocumentCMYK
/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
/GenerateStructure false
/IncludeBookmarks false
/IncludeHyperlinks false
/IncludeInteractive false
/IncludeLayers false
/IncludeProfiles false
/MultimediaHandling /UseObjectSettings
/Namespace [
(Adobe)
(CreativeSuite)
(2.0)
]
/PDFXOutputIntentProfileSelector /DocumentCMYK
/PreserveEditing true
/UntaggedCMYKHandling /LeaveUntagged
/UntaggedRGBHandling /UseDocumentProfile
/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice
|