Electromagnetic Extrusion Winding for Lower Flow Stress
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Solution Overview
Problem
The extrusion process for metal products, such as aluminum billets, often results in inconsistent material properties and tooling damage due to recrystallization and intermetallic compound growth, leading to inferior products and tooling deterioration.
Innovation Solution
An electromagnetic extrusion system that uses a magnetic field generated by an electromagnetic winding to reduce flow stress in the extrusion material, employing a magnetic flux density of at least 2 Tesla, which alters the material properties through magnetoplasticity, allowing for improved material flow and reduced pressure on tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional extrusion process is used with high temperature and pressure, then material can be pushed through the die, but recrystallization and intermetallic compound growth occur causing inconsistent material properties
Solution Approach 1:
The patent replaces the conventional thermal-mechanical extrusion system with an electromagnetic extrusion system. Electromagnetic windings generate a magnetic field that interacts with the conductive extrusion material, producing electromagnetic forces that drive material flow through the die. This substitution eliminates the need for high temperatures and mechanical press loads, preventing recrystallization and intermetallic compound growth while maintaining consistent material properties throughout the extruded product.
Solution Approach 2:
The patent fundamentally changes the extrusion process parameters from high temperature and high mechanical pressure to moderate temperature with electromagnetic field application. The magnetic field strength (typically 2-10 Tesla) and frequency are controlled to generate sufficient electromagnetic force for extrusion without causing thermal effects that would lead to recrystallization. This parameter change resolves the contradiction by achieving material flow through electromagnetic rather than thermal-mechanical means.
2Productivity
If high extrusion press loads are applied, then material flow through the die is achieved, but tooling damage and wear occur
Solution Approach 1:
The patent replaces high mechanical press loads with electromagnetic forces for driving material flow. The electromagnetic force is generated by the interaction between the magnetic field from the windings and the induced currents in the conductive extrusion material. This allows high extrusion rates to be achieved without applying damaging mechanical loads to the tooling, significantly extending tooling life while maintaining productivity.
3Ease of operation
If high temperature is used to facilitate material flow, then extrusion process proceeds, but intermetallic compounds grow and material properties deteriorate
Solution Approach 1:
The patent replaces thermal heating with electromagnetic forcing to achieve material flow. The electromagnetic field generates body forces within the conductive material that drive flow without requiring high temperatures. This eliminates the thermal conditions that cause intermetallic compound growth and microstructural deterioration, while still achieving ease of operation through the body forces generated by the electromagnetic interaction.
Solution Approach 2:
The patent changes the controlling parameter for material flow from temperature to electromagnetic field strength. Instead of heating the material to improve flowability, the magnetic field intensity and frequency are adjusted to generate appropriate electromagnetic forces. This parameter change resolves the contradiction by decoupling material flowability from thermal effects, allowing flow without the harmful high-temperature side effects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves more uniform deformation, reduces tooling wear, and enables the production of complex shapes with lower extrusion press loads, increasing tooling life and production efficiency while maintaining the extrusion material in a solid state with minimal heat generation.
Implementation Method 1
an applied magnetic field can change the plastic behavior of crystalline materials, a phenomenon known as magnetoplasticity
Implementation Method 2
an electromagnetic winding disposed about the chamber, which is configured to carry an electrical current to generate a magnetic field
Data Source
AI summary
A system and method for an improved material flow through an extrusion machine by altering the material properties in a magnetic field are provided. The electromagnetic extrusion system includes a ram that is moved into a chamber containing an extrusion material to force the extrusion material out of an opening defined, at least in part, by a die to create an extrusion with a cross-sectional shape corresponding to the predetermined shape of the opening. An electromagnetic winding of electrically conductive material is embedded within a tool retainer block surrounding the container and is helically wound about the chamber and carries a DC electrical current to generate a magnetic field having a magnetic flux density of at least 2 Tesla within the extrusion material to dissipate dislocation defect structures in the extrusion material being extruded via the magnetoplasticity effect. The magnetic field therefore provides for reduced flow stress on the tooling.