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Study of Effects of Variations in Process Parameters on the Extrusion Process

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Study of Effects of Variations in Process Parameters on the Extrusion
Process by Use of Finite Element Simulations

Amin Farjad Bastani, Benteler Aluminum System AS, Raufoss, Norway
Trond Aukrust, SINTEF MK, Oslo, Norway
Sverre Brandal, Hydro Aluminum ASA, Karmøy, Norway

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

ABSTRACT—There is a significant demand to reduce variations in shape and mechanical
properties of extruded sections. Variations in flow and temperature evolution during the extrusion
process are some of the sources to such variations. In this work, axi–symmetric finite element
simulations of a generic case with two exits at different radial positions have been performed to
study how variations in process parameters influence variations in exit speed and exit
temperature. The effects of variations in ram speed, billet temperature, initial billet temperature
gradient (taper), and container cooling have been studied. For each set of process parameters the
simulations have been done over 20 press cycles with two different finite element software. Two
types of variations have been studied. The first involved variations in flow balance or differences
in exit velocity and temperature between the two exits. The second involved variations in the
average exit temperature over the press cycle, with the aim of determining conditions for
isothermal extrusion. Effects of each of the process parameters on flow balance, temperature
evolution, and conditions for isothermal extrusion have been presented and discussed.

© 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.