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Application of Numerical Simulation Technology to Optimize Die Designs

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Application of Numerical Simulation Technology to Optimize Die
Designs for the Production of Complex Aluminum Profiles

Shengqian Xiang, Chunrong Zhou, and Yuehua Cai, Guangdong Haomei Aluminum Co.
Ltd., Qingyuan, Guangdong, China
Lei Cheng, Shuisheng Xie, and Youfeng He, Beijing General Research Institute for
Nonferrous Metals, Beijing, China

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

ABSTRACT—Although still having certain limitations, numerical simulation technology has
been increasingly applied to aid in optimizing the aluminum extrusion process and die design. Up
till now, the application of the technology to the process to produce large, complex profiles has,
however, been quite limited. In the present research, numerical simulations of the extrusion
process to produce large, complex hollow profiles in the non-steady state and in the steady state
were performed, using the Finite Volume Method (FVM) and Finite Element Method (FEM) to
make use of the individual merits of the Eulerian approach and Arbitrary Lagrangian-Eulerian
(ALE) approach, respectively. The metal flow through porthole dies was studied in two practical
cases. The formation of weld seams was explicitly revealed. Non-uniform velocities at the die
exit, leading to extrudate distortions, were predicted. Extrusion experiments proved that the die
with the optimized design could circumvent the distortion problem. The numerical simulation
technology can indeed be effectively used to reduce the number of die trials and offer the
potential to realize zero die trial.

© 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.