Simulation of a New Process Design to Fabricate a Rectangular Twist Waveguide Using Extrusion and a Twist Die

Authors

1 Department of Materials Science and Engineering, School of Engineering, Shiraz University, Shiraz, Iran

2 Department of Materials Science and Engineering, School of Engineering, Shiraz University, Iran.

Abstract

The aim of the present study is to determine the feasibility of making a rectangular twist waveguide used to rotate electromagnetic waves. For this purpose, the process of fabricating an aluminum rectangular twist waveguide was simulated by making use of finite element method and Deform software. The optimum length and angle of the twist die for manufacturing a twist waveguide with inner cross sectional dimensions of 22.86 mm × 10.16 mm and a length of 50 mm and twisting angle of 90 degrees were investigated. Moreover, the effect of certain factors such as the length, thickness, cross section dimensions of the waveguide and friction on the optimum length of the twist die and cross sectional distortion was studied. The results of this study indicated that the length of the twist die had an influence on the amount of twisting, while friction was of no importance. In addition, comparing the values of effective stress and flow stress at the cross section of the workpiece behind the twist die depicted that the workpiece would not yield behind the twist die due to smaller values of effective stress.

Keywords


[1] U. A. Bakshi, A. V. Bakshi, Transmission Lines and Waveguides, Technical Publications, Pune (2009), pp. 1-1-1-2.
[2] V. S. Bagad, Microwaves and Radar, Technical Publications, Pune (2008), pp. 2-1-2-2.
[3] M. Sharififar, S. A. A. Akbari Mousavi, Simulation and optimization of hot extrusion process to produce rectangular waveguides, The International Journal of Advanced Manufacturing Technology 79 (2015) 1961-1973.
[4] A. S. Khan, Microwave Engineering: Concepts and Fundamentals, CRC Press, Boca Raton (2014), pp. 170-171.
[5] G. E. Dieter, D. J. Bacon, Mechanical Metallurgy, McGraw-Hill, New York (1986) 616-617.
[6] M. M. Moshksar, R. Ebrahimi, An analytical approach for backward-extrusion forging of regular polygonal hollow components, International journal of mechanical sciences 40 (1998) 1247-1263.
[7] S. H. Kim, S. W. Chung, S. Padmanaban, Investigation of lubrication effect on the backward extrusion of thin-walled rectangular aluminum case with large aspect ratio, Journal of Materials Processing Technology 180 (2006) 185-192.
[8] N. R. Chitkara, A. Aleem, Axi-symmetric tube extrusion/piercing using die–mandrel combinations: some experiments and a generalised upper bound analysis, International journal of mechanical sciences 43 (2001) 1685-1709.
[9] S. Hansson, Simulation of Stainless Steel Tube Extrusion, Doctoral dissertation, Luleå University of Technology, Sweden (2006).
[10] L. De Pari, W. Z. Misiolek, Numerical modeling of copper tube extrusion: Process and eccentricity analysis, Journal of Manufacturing Science and Engineering 134 (2012) 051005.
[11] J. Lof, Y. Blokhuis, FEM simulations of the extrusion of complex thin-walled aluminium sections, Journal of Materials Processing Technology 122 (2002) 344-354.
[12] J. M. Lee, B. M. Kim, C. G. Kang, Effects of chamber shapes of porthole die on elastic deformation and extrusion process in condenser tube extrusion, Materials & Design 26 (2005) 327-336.
[13] H. H. Jo, S. K. Lee, C. S. Jung, B. M. Kim, A non-steady state FE analysis of Al tubes hot extrusion by a porthole die, Journal of Materials Processing Technology 173 (2006) 223-231.
[14] W. Xianghong, Z. Guoqun, L. Yiguo, M. Xinwu, Numerical simulation and die structure optimization of an aluminum rectangular hollow pipe extrusion process, Materials Science and Engineering: A 435–436 (2006) 266-274.
[15] G. Liu, J. Zhou, J. Duszczyk, FE analysis of metal flow and weld seam formation in a porthole die during the extrusion of a magnesium alloy into a square tube and the effect of ram speed on weld strength, Journal of Materials Processing Technology 200 (2008) 185-198.
[16] L. Li, H. Zhang, J. Zhou, J. Duszczyk, G. Y. Li, Z. H. Zhong, Numerical and experimental study on the extrusion through a porthole die to produce a hollow magnesium profile with longitudinal weld seams, Materials & Design 29 (2008) 1190-1198.
[17] C. Zhang, G. Zhao, Z. Chen, H. Chen, F. Kou, Effect of extrusion stem speed on extrusion process for a hollow aluminum profile, Materials Science and Engineering: B 177 (2012) 1691-1697.
[18] C. Zhang, G. Zhao, H. Chen, Y. Guan, F. Kou, Numerical simulation and metal flow analysis of hot extrusion process for a complex hollow aluminum profile, The International Journal of Advanced Manufacturing Technology 60 (2012) 101-110.
[19] D. Y. Yang, T. Altan, Analytical and experimental investigation into lubricated three-dimensional extrusion of general helical sections, CIRP Annals - Manufacturing Technology 35 (1986) 169-172.
[20] D. Y. Yang, K. Lange, Investigation into non-steady-state three-dimensional extrusion of a trocoidal helical gear by the rigid-plastic finite element method, CIRP Annals - Manufacturing Technology 43 (1994) 229-233.
[21] Y. B. Park, J. H. Yoon, D. Y. Yang, Finite element analysis of steady-state three-dimensional helical extrusion of twisted sections using recurrent boundary conditions, International Journal of Mechanical Sciences 36 (1994) 137-148.
[22] H. Yoshida, Y. Sawaki, Y. Sakaida, Shaping of helical gear by two-step cold extrusion, Materials transactions 49 (2008) 1162-1167.
[23] N. B. Khalifa, A. E. Tekkaya, Newest developments on the manufacture of helical profiles by hot extrusion, Journal of Manufacturing Science and Engineering 133 (2011) 061010-061010.
 [24] Y. M. Hwang, C. N. Chang, Hot extrusion of hollow helical tubes of magnesium alloys, Procedia Engineering 81 (2014) 2249-2254.
[25] Military Standardization Handbook, Fabrication of Rigid Waveguide Assemblies (Sweep Bends and Twists), Military Specification of the Department of Defense of the United States of America (2012).
[26] N. Pardis, R. Ebrahimi, Deformation behavior in Simple Shear Extrusion (SSE) as a new severe plastic deformation technique, Materials Science and Engineering: A 527 (2009) 355-360.
[27] P. Eskelinen, Introduction to RF Equipment and System Design, Artech House, Norwood (2004), pp. 146-147.