Dedicated Material Models of EN AW-7021 Alloy for Numerical Modeling of Industrial Extrusion of Profiles.

Abstract

In this paper, dedicated material models were developed and verified for three melts of EN AW-7021 alloy, differing in zinc and magnesium content, for tube extrusion conditions. Based on the plastometric tests, it was found that in the studied range of strain parameters, the analyzed melts of the same aluminum alloy showed different sensitivity to strain rate and temperature. In addition, a significant effect of magnesium and zinc content on the plasticity of the tested material was observed. Therefore, dedicated material models describing stress changes were developed for each melt analyzed. The models were then implemented into the material database of the QForm-Extrusion^® program, which was used for the theoretical analysis of the industrial extrusion process. In order to verify the results of numerical calculations, industrial tests of the extrusion process were carried out. The force parameters and the rate of the extrusion process were mainly analyzed. The use of dedicated material models for each melt contributed to the accuracy of numerical modeling. A high degree of compliance was obtained regarding the theoretical and experimental extrusion force and the velocity of metal flowing out of the die cavity, among others.