Magnetic-Field Extrusion for Uniform Metal Flow and Lower Tool Load
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Solution Overview
Problem
The extrusion process for metal products, such as aluminum, often results in inconsistent material properties and tooling damage due to recrystallization and intermetallic compound growth, leading to inferior products and tooling wear.
Innovation Solution
An electromagnetic extrusion system that uses a magnetic field generated by an electromagnetic winding to reduce flow stress in the extrusion material, improving material flow and uniformity by altering material properties through magnetoplasticity, thereby reducing pressure on tooling and enabling more complex shapes with lower extrusion press loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional extrusion process is used with high extrusion temperature, then material flow is improved, but recrystallization and intermetallic compound growth occur causing inconsistent material properties
Solution Approach 1:
The patent applies magnetic field as a new parameter to alter material properties during extrusion. The electromagnetic winding generates a magnetic field that modifies the flow stress characteristics of the extrusion material, enabling improved material flow without relying solely on high temperature, thus preventing unwanted recrystallization and intermetallic compound growth
Solution Approach 2:
The patent replaces part of the thermal-mechanical extrusion system with an electromagnetic system. Instead of using only mechanical pressure and thermal energy to drive material flow, an electromagnetic field is introduced to directly influence the material's flow stress, reducing dependence on high extrusion temperatures that cause material property inconsistencies
2Force
If high extrusion press load is applied, then material flow stress is overcome, but tooling damage occurs
Solution Approach 1:
The magnetic field generated by the electromagnetic winding changes the flow stress parameter of the extrusion material. By reducing flow stress through magnetic field application, the extrusion process requires lower press loads, thereby reducing mechanical stress on the tooling and preventing tooling damage while still achieving adequate material flow
Solution Approach 2:
The electromagnetic field acts as an intermediary between the extrusion press and the material. Instead of directly applying high mechanical loads that damage tooling, the magnetic field mediates the process by altering material properties, allowing lower press loads to achieve the same extrusion effect, thus protecting the tooling
3Ease of operation
If electromagnetic winding is added to reduce flow stress, then material flow improves, but device complexity increases
Solution Approach 1:
The electromagnetic winding serves multiple functions: it generates the magnetic field needed to reduce flow stress, and can potentially serve as part of the structural assembly during extrusion. This multi-functionality helps offset the added complexity by consolidating functions rather than adding separate independent systems
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 allows for faster production with fewer impurities and lower extrusion temperatures, enhancing the quality and efficiency of the extrusion process.
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
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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.