Farhad Parvizian

Application of Adaptive Mesh and ALE Method in Simulation of Extrusion of Aluminum Alloys

The purpose of this work is the modeling and simulation of the material behavior of aluminum alloys during extrusion processes. In particular, attention is focused here on aluminum alloys of the 6000 series (Al-Mg-Si) and 7000 series (Al-Zn-Mg). The material behavior of these alloys during extrusion is governed mainly by dynamic recovery and static recrystallization during cooling. The current material model is based on the role of energy stored in the material during deformation, as it acts as the driving force for microstructural development. The concept of internal variables is used to describe state quantities such as dislocation density, average grain size and average grain orientation. The focus of the current paper is on some of the numerical aspects of the extrusion process simulation such as contact problems and adaptive mesh refinement which should be considered in order to obtain more accurate and robust results.

Modeling of microstructure evolution in aluminum alloys during hot extrusion

The purpose of this work is the modeling and simulation of aluminum alloys during extrusion processes. In particular, attention is focused here on aluminum alloys of the 6000 series (Al-Mg-Si) and 7000 series (Al-Zn-Mg). In the current paper, a number of aspects of the structural simulation as well as that of extrusion as a thermomechanical process are considered. These aspects include contact and adaptive mesh refinement, heat transfer inside the billet, heat transfer between the workpiece and the container, frictional dissipation, mechanical energy and surface radiation. The friction is considered to model the so called “dead material zone”. The radiation constant has been estimated so that the results are close to the experimental results.

Modeling and Simulation of Microstructure Evolution in Extruded Aluminum Profiles

The purpose of this work is to predict the microstructure evolution of aluminum alloys during hot metal forming processes using the Finite Element Method (FEM). Here, the focus will be on the extrusion process of aluminum alloys. Several micromechanical mechanisms such as diffusion, recovery, recrystallization and grain growth are involved in various subsequent stages of the extrusion and the cooling process afterward. The evolution of microstructure parameters is motivated by plastic deformation and temperature. A number of thermomechanical aspects such as plastic deformation, heat transfer between the material and the container, heat generated by friction, and cooling process after the extrusion are involved in the extrusion process and result in changes in temperature and microstructure parameters subsequently. Therefore a thermomechanically coupled modeling and simulation which includes all of these aspects is required for an accurate prediction of the microstructure evolution. A brief explanation of the isotropic thermoelastic viscoplastic material model including some of the simulation results of this model, which is implemented as a user material (UMAT) in the FEM software ABAQUS, will be given. The microstructure variables are thereby modeled as internal state variables. The simulation results are finally compared with some experimental results.