Evaluation of Finite Element Codes for the Simulation of Aluminum Extrusion Process

2017 ◽  
pp. 53-64
Author(s):  
Tushar Bakhtiani ◽  
Jing Zhang ◽  
Hazim El-Mounayri
Keyword(s):  
Finite Element ◽  
Extrusion Process ◽  
Aluminum Extrusion

Study of Flow Balance and Temperature Evolution over Multiple Aluminum Extrusion Press Cycles with HyperXtrude 9.0

2009 ◽  
Vol 424 ◽  
pp. 257-264 ◽  
Author(s):  
Amin Farjad Bastani ◽  
Trond Aukrust ◽  
Inge Skauvik
Keyword(s):  
Finite Element ◽  
Finite Elements ◽  
Extrusion Process ◽  
Aluminum Extrusion ◽  
Billet Temperature ◽  
Exit Velocity ◽  
Extrusion Press ◽  
Flow Balance ◽  
Exit Temperature ◽  
Ram Speed

In this research, transient finite element simulations of the aluminum extrusion process have been performed in order to study how process parameters influence flow balance and exit temperature. This has been achieved by investigating the influence of billet taper, front billet temperature and ram speed on the run-out velocity and temperature of two separate outlets. Analysis of variance (ANOVA) has been employed to study the effect of each parameter on the velocity and temperature variation of the extruded section. Results show that increasing each of these three parameters results in an undesired increase in exit velocity and temperature. The front billet temperature is found to be the most significant factor affecting the variation. The finite elements software used was Altair HyperXtrude 9.0.

scholarly journals Modelling and Simulation of Hollow Profile Aluminum Extruded Product

2015 ◽  
Vol 761 ◽  
pp. 17-21
Author(s):  
Hani Mizhir Magid ◽  
Shamsuddin Sulaiman ◽  
M.K.A. Ariffin ◽  
B.T. Hang Tuah bin Baharudin
Keyword(s):  
Finite Element ◽  
Material Selection ◽  
Extrusion Process ◽  
Two Dimensions ◽  
Modelling And Simulation ◽  
Aluminum Extrusion ◽  
Entrance Angle ◽  
Die Geometry ◽  
Billet Material ◽  
Set Up

The main objectives of this paper is to find the way for solving the problems of aluminum extrusion process, and improve the mechanical properties of the products through a smart design, modelling and simulation of this process by using finite element method (FEM). For the purpose to model a (2D) two dimensions warm aluminum extrusion process, ABAQUS software was used to set up the finite element simulation. The main parameters which have major effects on this process like extrusion stresses, temperature, and die geometry, i.e. extrusion radius, were taken into consideration. Aluminum alloy (Al-2014) was used as the billet material, with 40 mm diameter and 75 mm length. It is important to preheat the billet from the beginning to a specific temperature, and then pressurizes it into the die. This process is an isothermal process with an extrusion ratio of 3.3. Subsequently, the optimized algorithm for these extrusion parameters was suggested based on the simulation results. The results suggest that the large die angle needs a less extrusion load than the small die angle. In all die geometry used, the deformation of aluminum billet, which caused by shearing and compression stresses, happened in a small sectional area, i.e., bearing area. The results also showed that the values of these stresses can increase or decrease depends on the die entrance angle and the die bearing length. To avoid the effects of these stresses on die dimensions; the hardness, material selection, and geometry should be well calculated.

Simulation of initial cooling rate effect on the extrudate distortion in the aluminum extrusion process

2012 ◽  
Vol 40 ◽  
pp. 326-336 ◽  
Author(s):  
S. Bikass ◽  
B. Andersson ◽  
A. Pilipenko ◽  
H.P. Langtangen
Keyword(s):  
Cooling Rate ◽  
Extrusion Process ◽  
Rate Effect ◽  
Aluminum Extrusion ◽  
Extrudate Distortion

Modeling of Aluminum Extrusion Process Using Non-Orthogonal Block Structured Grids Based FVM

2011 ◽  
Vol 189-193 ◽  
pp. 1749-1752
Author(s):  
Rui Wang ◽  
Hong Zhong Li
Keyword(s):  
Mathematic Model ◽  
Extrusion Process ◽  
Special Treatment ◽  
Aluminum Extrusion ◽  
Rigid Plastic ◽  
Structured Grids ◽  
Simulation Results ◽  
Flow Theories ◽  
Volume Method ◽  
Die Extrusion

The mathematic model of 3D aluminum extrusion processes using finite volume method (FVM) was established in this paper. The basic theories and rigid-plastic flow theories of this model were researched and built. Non-orthogonal structured grids were used to match complex geometric boundaries and local refinement of grids was also realized. The collocated arrangement is used to discretize the governing equations on non-orthogonal grids directly, pressure oscillations bring by this arrangement and error caused by grid’s non-orthogonality is eliminated by special treatment. A pocket die extrusion process was simulated using the program developed in this paper. The simulation results were also compared with that simulated by FEM software Deform in the same process, material and die conditions. The feasibility and efficiency of the mathematic model built in this paper was demonstrated by the simulation results and the comparison.

scholarly journals Measuring the Deformation of a Flat Die by Applying a Laser Beam on a Reflecting Surface

2009 ◽  
Vol 424 ◽  
pp. 197-204 ◽  
Author(s):  
W. Assaad ◽  
H.J.M. Geijselaers ◽  
K.E. Nilsen
Keyword(s):  
Finite Element ◽  
Laser Beam ◽  
Extrusion Process ◽  
Trial And Error ◽  
Element Calculation ◽  
Extrusion Dies ◽  
Cheap Method ◽  
Trial And Error Method ◽  
Reflecting Surface ◽  
Error Method

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. The die is designed by a trial and error method which is expensive interms of time consumption and the amount of scrap. Research is going on to replace the trial pressing with finite element simulations that concentrate on material and tool analysis. In order to validate the tool simulations, an experiment is required for measuring the deformation of the die. Measuring the deformation of the die is faced with two main obstacles: high temperature and little free space. To overcome these obstacles a method is tried, which works by applying a laser beam on a reflecting surface. This cheap method is simple, robust and gives good results. This paper describes measuring the deformation of a flat die used to extrude a single U shape profile. In addition, finite element calculation of the die is performed. Finally, a comparison is performed between experimental and numerical results.

Investigation of Corner Cavity Formation During Backward Cup Extrusion Process Using Finite Element Method

2009 ◽  
Author(s):  
Arash Khajeh ◽  
Ramin Ebrahimi ◽  
Mohammad Mohsen Moshksar
Keyword(s):  
Finite Element ◽  
Extrusion Process ◽  
Critical Value ◽  
Cavity Formation ◽  
Element Analysis ◽  
Temporal Prediction ◽  
Element Simulation ◽  
The Finite Element Analysis ◽  
Considerable Impact ◽  
Reduction Of Area

This study focuses on the finite element analysis of the formation of corner cavity defect during the Backward Cup Extrusion (BCE) process. In the final stage of this process, when the bottom thickness reaches to a critical value this defect will be appear as a circumferential defect in the corner of the cup. In addition, this research examines the temporal prediction of onset of corner cavity formation in the various amounts of the reduction of areas. The finite element simulation results were compared with those of the experimental, indicating that the amount of the reduction of area and that of the friction coefficient have considerable impact on the onset of corner cavity formation during the BCE process.

The Inverse Prediction for Profile Extrusion Die Based on the Finite Element Method

2014 ◽  
Vol 941-944 ◽  
pp. 2332-2335 ◽  
Author(s):  
Min Zhang ◽  
Chuan Zhen Huang ◽  
Yu Xi Jia ◽  
Jin Long Liu
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Polymer Melt ◽  
Simulation Method ◽  
Extrusion Process ◽  
The Finite Element Method ◽  
Polymer Extrusion ◽  
Extrudate Swell ◽  
Extrusion Die ◽  
Element Method

Considering the extrudate swell, the polymer extrusion process was calculated by the inversed simulation based on the visco-elastic ecology theory. The fluid characteristics of the polymer melt were described by the Phan-Thien and Tanner (PTT) model. The Finite Element Method was used. Based on the simulation data, the extrusion die lips were analyzed. So it is feasible to design the polymer extrusion die lips using inversed simulation method.

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