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3-D Numerical Simulation of Direct Aluminum Extrusion and Die Deformation

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3-D Numerical Simulation of Direct Aluminum Extrusion and Die Deformation

W.A.Assaad, University of Twente Enschede, The Netherlands
H.J.M. Geijselaers, University of Twente Enschede, The Netherlands
J. Huétink, University of Twente Enschede, The Netherlands

Track: EXTRUSION/DIE, THEORETICAL - Modeling and Simulation

ABSTRACT --- The design of extrusion dies depends on the experience of the
designer. After the die has been manufactured, it is tested during an extrusion
process and machined several times until it works properly. Therefore, the die is
designed by a trial and error method which is an expensive process. In addition,
after several runs the die may deform. This may lead to an unacceptable product.
This paper focuses on 3-D simulation of a direct aluminum extrusion process.
The behavior of the billet and die is predicted. In the simulation an Eulerian
formulation is applied to simulate the flow of the material, rather than an
Updated Lagragian formulation with remeshing. Finally, the results will illustrate
how the die deforms and whether it deforms elastically or plastically and the
influence of die deformation on the extruded product dimensions.

© 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.

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