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Vol 85, July 2004
INTRODUCTION
Several attempts have been made to analyse the cold as well ashot extrusion problems. Some of them for cold cases are due toMehta,
et al
 
1
, Nagpal
2
, Yang and Lee
3
, Yang,
et al
 
4-7
, Gattoand Giarda
8
, Kiuchi,
et al
 
9
, Gunasekera and Hoshino
10
,Boer and Webster
11
, Kudo
12
, Lee,
et al
 
13
, Balaji,
et al
 
14
, Shim,
et al
 
15
, Joun and Hwang
16, 17
and most recently by Kumar,
et al
 
18, 19
. These works have reported different solutionapproaches using upper bound, slip-line field and finite elementmethods. Gunasekera and Hoshino
10
proposed an upper boundsolution for streamlined dies and concluded that streamlined diesare superior to straight converging dies for reducing extrusionpressure in cold condition. However, none of these solutions areof a general nature applicable to all non re-entry shapes exceptKumar,
et al
 
18, 19
that uses a feature-based upper-bound modelwith strain hardening suitable for die analysis of non re-entry coldextrudable shapes.In case of hot extrusion, some of the notable attempts made areby Johnson and Kudo
20
, Sheppard and Raybould
21
, Altan andKobayashi
22
, Altan,
et al
 
23
, Sheu and Lee
24
, Tay,
et al
25
,Zienkiewicz,
et al
 
26
, Smelsor
27
and Reddy,
et al
 
28
. Faren andTaylor
29
measured the plastic work and temperature rise intensile test and found that for steel, copper and aluminium, theheat rise represents, respectively 86.5%, 90.2% to 92% and 95%of plastic work, respectively. Singer and Coakham
30
made anattempt to predict the emergent temperature of the extrudedproduct by taking a simple model in which completedeformation takes place at the exit cross-sectional plane of theflat die assuming heat flows only in axial direction. Reddy,
et al
28
analysed eight die profiles and found third order andcosine die profiles to be the best, whereas, conical dies requiring,maximum extrusion power. Reddy,
et 
 
al
31
proposed a finiteelement thermal model to determine the temperature distributionin an axisymmetric hot extrusion process based on thedeformation field obtained by upper bound model.In the present work, a feature based upper bound modelproposed by Kumar,
et al
 
18, 19
has been used to propose acombined upper bound-rigid plastic finite element (UB-RPFE)model for axisymmetric cold and hot extrusion. Results obtainedfrom the combined model have been validated for cold and hotextrusion and are found close to the experimental and analyticalresults reported earlier by Singer and Coakham
30
and Reddy,
et al
31
. Parametric study is also carried out using a third orderstream-lined die profile to study the effect of various parameterslike extrusion ratio, friction factor, ram velocity, die length andtemperatures (initial billet, container and surrounding) onextrusion stress and temperature of the extrudate. It is found thatextrusion power varies with the die length, ram velocity, extrusionratio, friction factor, temperature etc. Optimal die length, whichminimises the extrusion power, is also determined using goldensection search method.
UPPER BOUND FORMULATIONConstitutive Equation
The strain rate tensor
&
Î
ij
is given as
&
Î = +æèç ç öø÷  ÷  
iji j ji
v xv x
12
(1)where
v
i
 
and
v
 j
represent the velocity components along
 x
i
 
and
A Finite Element Thermal Model for Axisymmetric Cold and HotExtrusion using Upper Bound Technique
Dr S Kumar,
 Non-member 
S K Prasad
 , Non-member 
 In this paper, a combined rigid plastic finite element (RPFE) model for steady state axisymmetric extrusion process is proposed using a kinematically admissible velocity field obtained from the upper bound model earlier proposed by Kumar,et al. Optimal power and temperature distribution in cold as well as hot extrusion processes are determined 
with RPFE method using the deformation field obtained from upper bound method. Effects of various process parameters, such, as,ram velocity, reduction, friction between die billet interface, die length and temperatures (initial billet, die and container and surrounding) has been analysed using the proposed combined UB-RPFE method. The result obtained agrees wellwith the experiment and analysis. The proposed model can further be extended for generalized solid shaped extrusion for both hot and cold cases.
 Keywords:
 
Extrusion, Upper bound method; Finite element thermal formulation; Penalty method
Dr S Kumar and S K Prasad are with the Department of MechanicalEngineering, Institute of Technology, Banaras Hindu University,Varanasi 221 005.
This paper (revised) was received on September 16, 2003. Writtendiscussion on the paper will be entertained till September 30, 2004.
59
 
 IE(I) Journal-MC 
 x
 j
 
directions, respectively. The constitutive law for rigid plastic/ viscoplastic material relating the deviatoric stress tensor
¢s
ij
andthe strain rate tensor
&
Î
ij
is expressed as
¢= Îs m
ij ij
2
&
where
m
is the Levy-Mises coefficient. The generalized yield stress
s
and generalized strain rate
Î
are defined as
s s s=¢ ¢
32
ij ij
and
&& &
Î= Î Î
23
ij ij
(2)generalized strain
Î
is therefore, defined as
Î= Î
ò
&
d
t 
t 
0
(3)In general
s
depends on
Î
,
&
Î
and temperature
T 
.
( )
s = Î Î
F 
,
&
,
T 
(4)In case of cold extrusion the effect of temperature can beneglected on generalised stress
s
. These equations are used inthe proposed upper bound solution.
General Methodology
The upper bound theorem
32
can be expressed as
j s W D
T i
ij ij S i
=¢Î
ò ò
 W
***
&
d+d
t
v S
t S
i
(5)where
 W
is the plastic deformation zone,
t
is the shear stress onvelocity discontinuity surfaces.The first term expresses the internal power of deformation overthe volume of the deformation zone, while the second termrepresents the power dissipated in shearing the material over thevelocity discontinuity surfaces and at the tool-work interface (
ie
,frictional power). Here, asterisk (*) indicates that the values of stress, strain rate and velocity discontinuity are obtained from anassumed kinematically admissible velocity field.
Proposed Kinematically Admissible Velocity and Strain RateFields
The geometry of die and the velocity field in terms of streamlinesin the steady flow process of extrusion are shown in Figure 1.Velocity boundary conditions and the feature recognitionmethodology proposed by Kumar,
et al
 
19
for general class of extrudable components for slicing the deformation zone, hasbeen used in the present model.One power element
OMM´O´N´NO
is chosen to demonstratethe analytical construction of velocity and strain rate fields. InFigure 2 the billet with an initial radius (
 R
o
) at entry, is extrudedthrough a shaped (converging) dies constructed by a number of pre-defined streamlines representing the surface of die, to the finalgeneralised given section at the exit.In order to construct the kinematically admissible velocity fieldshown in Figure 2, the assumptions made are :(i)Material of billet passing through the sector
OMN 
at theentry goes through the triangle
O´M´N´ 
at the exitpreserving the extrusion ratio.(ii)Stream surface
ONN´O´ 
consists of a number of streamlines (curved or straight) which start from a point(say
P
) at entry and end at a corresponding point (
P
´) atexit, maintaining the proportionality of the position.(iii)The material is incompressible, rigid, and perfectly plasticwhich follows a particular strain-hardening curve.
Figure 1 Geometry of extrusion die and streamlines having generalised sec-tionFigure 2
 
The domain and boundary conditions (thermal) for axisymmetricextrusion
60
 
Vol 85, July 2004
(iv)The deformation zone is bounded by straight plasticboundaries at entry and exit sections of the die.(v)The neutral line is the line joining
CG
of billet (
ie,
point
O
) and
CG
of the extruded product cross-section (
ie,
point
O
’
).(vi)The elastic strain is small and can be neglected.(vii)Friction factor between the die and work piece materialis assumed to be independent of slip.(viii)Deformation takes under place homogeneous and steadystate conditions.Assumptions (i) and (ii) state that the reduction ratio is keptconstant with the subdivision of the material into small elements.
ie
, for one power element
OMM´O´N´NO
Area of cross-section area on product side
D
O'M'N' 
æèç ø÷  
=
Area of cross-section area on billet side
D
OMN 
æç öø÷  
(6)If the coordinates of points
 M' 
 
and
 N' 
 
are (
 x
1
 , y
1
) and(
 x
2
,
y
2
), respectively and
 A
a
is the cross-sectional area of theextruded product shape.Then,
( )
¢ ¢= = +
O M a x y
11212
; and,
( )
¢ ¢= = +
O N a x y
22222
cos =
y
ba
1
a
2
where
b
= (+
 x x y y
1212
)
.From equation (6),
sin.
yfp=
Aa
a
 
12
a
The streamlines on the stream surface can be represented by athird order polynomial to satisfy the smooth entry and exit of thematerial flow. Any coordinate along the streamline
PP´ 
isformulated in a Cartesian coordinate system as
 x z z z z y z z z z z z
= = + + += = + + +=üýï þï 
f()bbbbf()cccc
11322342132234
(7)where b
i
and c
i
(for
i
= 1, 2, 3, 4) are constants, determined bythe boundary conditions. Since, the streamline does not produceany abrupt change in flow direction along the extrusion axis atentry and exit, the boundary conditions can be written as
 xx z y ny z z
= == =üýï þï =
n
sinatbilletside(0)
ff
;cos;00
(8)
 xna R x z yna R y z L
oo
= == =üýï ï þï ï =
2
00
2
sin;cos;
y y
at product side ()
 z
where
R
o
 
is the billet radius;
n
is the distance from the axisformed by joining the
CG
of the product and the billet shape(
ie, O – O' 
) to an arbitrary point
C 
at the die entry
f
and
y
arethe angles between the plane of symmetry and the stream surfaceat entry and exit of the die, respectively and
 L
is the die length.Substituting these boundary conditions from equation (8) intoequation (7) gives
 x n na R z
o
= + -æèç ø
 
÷  
sinsinsin()
fyf
2
f 
 y n na R z
o
= + -æèç ø÷  
coscoscos()
fyf
2
f 
(9)
 z
=
 z
where
ff 
= =æç ø÷  -æç ø÷  éëêêùûú  ú  
()
 zz L z L
32
23
(10)here f(
 z
) =0 at
 z
=0 and f(
 z
)=1 at
 z
=
 L
(11)Equation (9) not only describes the coordinates inside theplastically deforming region but the relationship between theCartesian and
n
,
 
f
,
z
coordinate systems also. Although thepresent analysis employs a third order curve represented byequation (10) for the description of die profile and theassumed streamlines of particles, it is to be noted thatfunction f(
 z
) in equation (9) can be any general function of 
 z
provided the function satisfies the given boundary conditions asgiven in equation (11).The Jacobian of equation (9) can be found as
 x nA nB
=f =+f =
+
 y nC nD z z
where
 A Bacon R A conAaa
oa
= = - =
sin;;
ffp
212
11
C Dacon Rcon
o
= = - =
cos;;cos
f y
2
22
C 
Hence
 J  A B C DnA nB nC nDnB nD
=+ ++ +éëêêêùûú  ú  ú  
ff ff ff 001''''''
61
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