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A Review of FEM Code Accuracy for Reliable Extrusion Process Analysis

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A Review of FEM Code Accuracy for Reliable Extrusion Process
Analysis: Extrusion Benchmarks 2009 and 2011

Lorenzo Donati 1, Nooman Ben Khalifa 2, Luca Tomesani 1, and A. Erman Tekkaya 2
1 DIEM Department, University of Bologna, Bologna, Italy,
2 Institute of Forming Technology and Lightweight Construction (IUL), Technische
Universität Dortmund, Dortmund, Germany

Track: EXTRUSION/DIE THEORETICAL - Benchmark, Finite-Element Method, Metal Flow

ABSTRACT—This paper presents an overview of the two previous editions of the benchmark
conferences (2009 and 2011) with a focus on experimental trials results and on the comparison of
the accuracy of the different FEM codes in predicting critical process outputs. Indeed benchmark
experiments are designed with the aim to focus the attention on a particular phenomenon and to
check the ability of FEM codes of predicting it. Profile lengths, process load, die deflections, die,
and profile temperatures which were accurately recorded during the extrusion strokes were used
as benchmarking parameters for FEM comparison. Moreover, computational times, simulation
set-up times, as well as information on the required hardware were compared for the proposed
cases study. A detailed discussion for all output parameters is described in order to illustrate the
evolution of the potentiality and limits of each code used in the last three years.

© Extrusion Technology for Aluminum Profiles Foundation (ET Foundation). All rights reserved. No part of The Proceedings may be reproduced in any form without the express written permission of the ET Foundation.