Title: Case studies on virtual extrusion of aluminium alloys in real size

Authors: G. Liu, J. Zhou, J. Duszczyk, G. Fang

Addresses: School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China. ' Department of Materials Science and Engineering, Delft University of Technology, Mekelweg 2, 2628 CD Delft, The Netherlands. ' Department of Materials Science and Engineering, Delft University of Technology, Mekelweg 2, 2628 CD Delft, The Netherlands. ' Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Abstract: Two case studies were conducted to illustrate the capabilities of the state-of-the-art computer simulation technology applied to the aluminium extrusion process and demonstrate the usefulness of virtual extrusion in real size to the die designer and extrusion process engineer alike. A deform 3D software package was used for virtual extrusion in real size to manufacture a hollow profile through a porthole die (case I) and two precision solid profiles through a two-hole multi-step pocket die (case II). Temperature, stress and velocity distributions were revealed. In case I, the filling of the ports, welding in the welding chamber and forming of the hollow profile were visualised. The quality of the longitudinal welds along the hollow profile length was assessed. In case II, the deflection of two solid profiles from the centreline to different extents was predicted, thereby providing the guidelines for die design modification. The modified die indeed performed better.

Keywords: finite element method; FEM; computer simulation; virtual extrusion; aluminium alloys; aluminium profile; porthole dies; pocket dies; weld quality; temperature distribution; stress distribution; velocity distribution; die design; design modification.

DOI: 10.1504/IJMPT.2011.039930

International Journal of Materials and Product Technology, 2011 Vol.40 No.3/4, pp.186 - 198

Accepted: 23 Apr 2010
Published online: 28 Feb 2015 *

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