FEM SIMULATION OF MANNESMANN PIERCING OF ALUMINUM ALLOY INGOTS

Mannesmann piercing of ingots, which were made of aluminum alloy by casting, was done using plugs of different shape: entire plug, plug with cavity and hollow plug. Plugs had same diameter of calibrating segment. Piercing was carried out at 400 °C ofbillets. Influence of plugs’ shape on variation of hollow shells’ diameter, wall thickness and density along their length was estimated. Hollow shells were cut into 15 equal rings to measure density using hydrostatic (Archimedean) weighing. Experimental operations were simulated using FEM computer software. Casting was simulated using ProCAST, piercing — using QForm. Variation of hollow shells’ diameter, wall thickness and density along their length was estimated after simulation had been done. Experimental and simulation data were compared to check FEM simulation accuracy. Difference between experiment and simulation for density was not more than 2 %, for hollow shells’ dimensions — 20 %. Conducted investigation allowed estimation of how plug’s shape affects hollow shells’ dimensions accuracy and density. It was established that hollow plug or plug with cavity, in terms of dimensions accuracy and density variation, are preferable for piercing. Each of plugs being used, provides manufacturing of hollow shells with maximum density for all volume except close to hollow shell’s edges domains, where density is 1 % less than maximum value.