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Practical Approach to Computer Simulation and Optimization

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Practical Approach to Computer Simulation and Optimization of
Complex Thin Profile Extrusion

N. Biba, A. Lishny, and S. Stebunov
QuantorForm Ltd., Moscow, Russia

Track: EXTRUSION/DIE THEORETICAL - Weld and Finite-Element Method

ABSTRACT—This paper presents the development and practical implementation of the finite
element (FE) model for simulation of thin aluminum profile extrusion that is included in the specialpurpose
program QForm-Extrusion. Due to non-uniform material flow, the profile that leaves the
orifice may bend, twist, or buckle. Other aspects of the material flow such as location of the seam
welds in hollow profile extrusion and the propagation of the charge weld in billet-to-billet extrusion
are also accurately predicted. The program has a special interface for quick die geometry import
and automatic generation of the FE model. The program automatically recognizes bearing zones
and converts them into parametric form, allowing modification of the bearing. Alterations and
optimization can be done by using the special module Bearing Editor with which the user can
achieve the most uniform distribution of longitudinal velocity. The simulation also provides
comprehensive analysis of the die stress and deflection. Reasonable simulation time is provided
by parallel computations. The software is currently in use at many die making and extrusion
companies demonstrating its high economic efficiency.

© 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.