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Application of FEM to Modeling of Multi-hole Die Extrusion

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Application of FEM to Modeling of Multi-hole Die Extrusion

Terry Sheppard and Zhi Peng, Bournemouth University

Track: EXTRUSION PROCESS - Peripheral Coarse Grain

ABSTRACT --- When extruding shaped sections that would normally require
pressures in excess of the press capacity, in cases when it is more productive to
extrude shorter lengths or when extruding forge stock, it is common to use multihole
dies. The literature describing or analysing such a process is sparse although
the industrial application is quite common. The majority of experimental extrusion
reported has been concerned with plane or axi-symmetric extrusion of sheet or rod.
There are few studies reported focusing on the pressure requirements or the
temperature variations and material flow when considering complex shapes or
multi-hole dies although these are important considerations to the press designer
and to the operator. This paper reports the use of a commercial finite element
method (FEM) code FORGE3® to study the influence of the number and the
distribution of die holes on extrusion parameters. The flow pattern, pressure
requirements, and temperature histories developed are established and it is clearly
shown by the FEM simulations that agreement with experimental results is
obtained. The metallurgical behavior (the substructure and the recrystallized grain
size) is obtained from these simulations and is used as a criterion for the optimal
distribution of the multi-hole configuration. Finally, the structures are compared with
extrusion through a single-hole die.

© 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.