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Analysis and Design Optimization of Aluminum Extrusion Dies

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Analysis and Design Optimization of Aluminum Extrusion Dies

Mahender P. Reddy, Ravisankar Mayavaram, David Durocher, and Håkan Carlsson, Altair Engineering
Ola Bergqvist, Altair Engineering AB

Track: DIE DESIGN AND TECHNOLOGY - Finite Element Method

ABSTRACT --- A numerical algorithm to analyze and optimize aluminum extrusion
dies is presented. Material flow and heat transfer in extrusion dies is analyzed using
a finite element model. Bearing area shape/length optimization influences metal flow
behavior and the quality of extruded product. The finite element model is coupled
with an optimization algorithm to compute optimum bearing lengths/shapes. The
paper describes the algorithm used to adjust bearing lengths in order to achieve a
balanced flow. Examples demonstrate how numerical methods complement existing
die design and analysis practices.

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