I-Peng Hsu's research while affiliated with National Sun Yat-sen University and other places

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Publications (1)

Figure 2. Geometric configurations of porthole channels of porthole dies. (a) Traditional die and (b) modified die.
Figure 3. Components of porthole dies. (a) Bridge and mandrel part, and (b) the outer die part.
Figure 4. Geometric parameters in the whole die; (a) top view and (b) longitudinal section view. Figure 4. Geometric parameters in the whole die; (a) top view and (b) longitudinal section view.
Figure 15. Loading curve during the expansion test for a tube section with a 300 mm distance from the stop-mark.
Figure 16. Appearances for a tube section taken at a position of 500 mm in front of the stop-mark. (a) Top view, and (b) side view.

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Die Design and Finite Element Analysis of Welding Seams during Aluminum Alloy Tube Extrusion
  • Article
  • Full-text available

May 2023

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1 Citation

Metals

Yeong-Maw Hwang

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I-Peng Hsu

Hollow tubes are generally manufactured using porthole die extrusion. A finite element software QForm is used to analyze the material flow of aluminum alloy A6061 tubes inside a specially designed porthole die during tube extrusion. High welding pressure and shorter transverse seam length are required for a sound product. Various extrusion conditions and die geometries and dimensions affect the bonding strength of the products. In this paper, the effects of die geometries on the welding pressure are discussed using the Taguchi method. The simulation results show that a higher welding pressure is obtained with a larger porthole radius, a larger welding chamber height, and a larger bearing length, while a larger bridge width increases the welding pressure slightly. For transverse seam lengths, a shorter transverse seam length can be obtained with a smaller porthole radius and a smaller welding chamber height, and a shorter bridge width and bearing length decrease the transverse seam length slightly. The transverse seam region and flow patterns are observed. Tube expanding tests were also conducted. From the expanding test results, it is known that the fracture position did not occur at the welding line and the bonding strength could reach up to 160 MPa.

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