Hollow Non-Circular Extrusion Using Shear-Assisted Material Flow
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Solution Overview
Problem
Existing manufacturing processes for producing hollow parts from materials like magnesium or aluminum are inefficient, require expensive rare earth metals, and lack the ability to form materials with desired grain sizes and corrosion resistance, while being energy-intensive and requiring additional processing steps.
Innovation Solution
A shear-assisted extrusion process that applies both rotational shearing and axial forces to the material using a scroll face with grooves, allowing plasticized material to flow through portals and recombine into desired shapes, reducing energy consumption and eliminating the need for preheating or additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional extrusion processes are used to produce hollow parts from magnesium or aluminum, then the parts can be manufactured, but the process requires expensive rare earth metals, high energy consumption, and additional processing steps
Solution Approach 1:
The patent combines multiple processing steps into a single extrusion operation. The feedstock material undergoes simultaneous homogenization, plastic deformation, and hollow profile formation in one continuous process, eliminating the need for separate preheating, forging, and extrusion steps required by conventional methods
Solution Approach 2:
The feedstock material's own plasticity and flow characteristics are utilized to form the hollow profile during extrusion. The material self-organizes into the desired hollow cross-section through the extrusion die geometry, eliminating the need for additional forming operations or costly alloying with rare earth metals
2Productivity
If conventional extrusion processes are used, then hollow parts can be produced, but the process is energy-intensive and requires preheating and additional processing steps
Solution Approach 1:
The feedstock material is pre-configured with the appropriate hollow cross-sectional geometry and material distribution before extrusion. This preliminary preparation allows the material to flow directly into the final product shape during extrusion, eliminating post-processing steps and reducing total manufacturing time
Solution Approach 2:
The extrusion process operates continuously without interruption for preheating, intermediate forming, or cooling stages. The material flows continuously from the extrusion die to form hollow profiles, maintaining productive action throughout the entire processing cycle and maximizing production efficiency
3Strength
If conventional extrusion is used to form hollow parts, then production is possible, but the material grain size and structure cannot be optimized for strength and corrosion resistance
Solution Approach 1:
The extrusion process parameters (temperature, pressure, strain rate) are optimized to control the material's plastic deformation behavior. By adjusting these parameters, the grain size and crystallographic structure of the extruded material can be precisely controlled to achieve desired strength and corrosion resistance properties
Solution Approach 2:
The extrusion process utilizes dynamic control of the deformation parameters during material flow. The varying stress state and strain rate during extrusion promote dynamic recrystallization and grain refinement, creating a optimized microstructure that enhances both strength and corrosion resistance without requiring additional heat treatment steps
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
Enables the production of lightweight, high-strength, corrosion-resistant materials with improved ductility and energy absorption, achieving significant cost savings and reduced energy consumption compared to conventional methods.
Implementation Method 1
simultaneously applying a rotational shearing force and an axial extrusion force to the same location on the feedstock material
Implementation Method 2
the grooves configured to direct plasticized material from a first location through a portal defined within the scroll face
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.