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Simulation and Experimental Investigations of Composite Extrusion Processes

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Simulation and Experimental Investigations of Composite Extrusion Processes

Marco Schikorra, Michael Schomäcker, Thomas Kloppenborg, and A. Erman Tekkaya
University of Dortmund, Dortmund, Germany

Track: EXTRUSION/DIE, THEORETICAL - Modeling and Simulation

ABSTRACT --- The application of composite extrusion to reinforce aluminum
profiles with continuous reinforcing elements to increase strength, stiffness, and
functionality is a promising production method for lightweight profiles, for
example, in aerospace engineering. Process control and detailed knowledge on
how to embed the endless high-strength reinforcement wires are absolutely
necessary to achieve an acceptable composite structure and positioning of the
reinforcement. Basic process experience is required due to the complex die
design needed to feed a large number of wires during the extrusion of thin-walled
and hollow profiles. This paper shows numerical investigations based on finite
element simulations as well as experimental investigations of several profile
geometries to study the influencing parameters regarding the stress level in the
reinforcement, material flow, positioning of the reinforcing elements, and die
design strategies. Based on these results, guidelines for tool and process design
will be shown to increase the process stability regarding reinforcement cracking,
insufficient composite quality, and poor positioning even for complex profile
shapes. Finally, numerical optimization of the die design and process parameters
was included in the numerical investigations to optimize the material flow and
the profile exit speed.

© 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.