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Effect of the Convex Die Geometry on the Process Parameters During Extrusion

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Effect of the Convex Die Geometry on the Process Parameters During Extrusion

Pawel Kazanowski -- Institute for Metal Forming, Lehigh University
Wojciech Libura -- AGH – University of Science and Technology
Romana Sliwa -- Rzeszow University of Technology


ABSTRACT --- The die geometry, as well as the extrusion process parameters
and relative motion of the press tooling, are responsible for metal flow. Based on
extensive experimental studies of metal flow in the extrusion process, a new type
of die, a convex die, was proposed in the last decade. The main idea behind the
convex die is to create radial metal flow toward the die opening. In the presented
work the boundaries of the deformation zone during direct extrusion through
convex dies are analyzed. The assumed boundaries are generalized, so that
their shape and location are functions of the process parameters, which can be
optimized. An upper bound approach was used to calculate the extrusion
pressures. Analysis of the results for a wide range of die angles above 90
degrees, extrusion ratios, and friction conditions provided useful predictions to
the formation of the deformation zone. Extrusion pressures calculated for
assumed boundaries with a radial metal flow zone near the convex die orifice are
in very good agreement with experimental data. It is possible to predict an
optimal range of die angles which maximize the radial metal flow component for
given material properties and process parameters.

© 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.