A novel application of sideways extrusion to produce curved aluminium profiles: Feasibility study

Wenbin Zhou (Lead / Corresponding author), Jianguo Lin, Trevor A. Dean, Liliang Wang

Research output: Contribution to journalConference articlepeer-review

21 Citations (Scopus)
28 Downloads (Pure)


Conventional curved aluminium alloy profile forming methods which depend on apparatus, additional to extrusion tooling, to bend extruded, straight sections inevitably decrease manufacturing efficiency and have to deal with springback and cross-sectional distortion. In this article, a novel energy-efficient forming method based on internal differential material flow, differential velocity sideways extrusion (DVSE), is proposed, which can directly form billets into curved profiles/sections by extrusion alone, using two opposing punches. A detailed study has been conducted and cold extrusion/bending of round bars and tubes was examined. It was found that curved profiles/sections with no distortion are formed, and adjustable profile curvature can be achieved by changing the velocity ratio of a slower lower punch to a faster upper punch and also extrusion ratio. Lower velocity ratio and larger extrusion ratio tend to increase the material flow velocity gradient at the die exit and lead to greater curvature. Effect of velocity ratio is greater than that of extrusion ratio, especially when velocity ratio is less than 1/3. Effect of the extrusion ratio is small when velocity ratio is greater than 0.5, after which the effect of extrusion ratio becomes more significant as velocity ratio decreases.

Original languageEnglish
Pages (from-to)2304-2309
Number of pages6
JournalProcedia Engineering
Early online date15 Nov 2017
Publication statusPublished - 2017
EventInternational Conference on the Technology of Plasticity, ICTP 2017 - Hucisko, United Kingdom
Duration: 17 Sept 201722 Sept 2017


  • Aluminium alloy profiles/sections
  • Bending
  • Curvature
  • Extrusion

ASJC Scopus subject areas

  • General Engineering


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