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Development of a Numerical Method for Simulation of Aluminum Extrusion Processes

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Development of a Numerical Method for Simulation of Aluminum
Extrusion Processes with Modeling of Microstructure

Andrea Ockewitz, Dong-Zhi Sun, and Florence Andrieux, Fraunhofer Institute
for Mechanics of Materials IWM, Freiburg, Germany
Soeren Mueller, Extrusion Research and Development Center FZS, TU Berlin, Berlin, Germany

Track: EXTRUSION/DIE THEORETICAL - Modeling, Microstructure and Simulation

ABSTRACT—Numerical simulation of extrusion processes offers an efficient method for tool
design and optimization of geometries and properties of extruded parts. However, until now there
are few systematic investigations about influences of material model and different parameters,
e.g., for friction and thermal processes on calculated local and global responses. In this work, a
numerical method for the simulation of extrusion processes with modeling of microstructure is
presented. Extensive testing was done to provide a basis for the verification of simulation results.
Circular rods of AA6005 were extruded by backward and forward extrusion for different
extrusion ratios, billet temperatures, and product velocities. The extruded rods were cooled either
by water or in air to distinguish between dynamic and static recrystallization. Temperature and
strain-rate dependent yield stresses were determined from hot compression tests. The
recrystallized volume fraction and grain sizes in the extruded rods were analyzed by means of
optical micrographs and EBSD scans. The obtained results were used to determine the parameters
of a recrystallization model which was implemented in the FE code HyperXtrude. The
transferability of the numerical model was checked by simulating forward extrusion tests using
the model parameters obtained from backward extrusion tests.

© 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.