The Model for Coupled Simulation of Thin Profile Extrusion

Abstract

The paper presents the latest development of the numerical model for extrusion of industrial profiles having complex shapes. The model provides the material flow analysis coupled with mechanical and thermal problems in the tooling set. The simulation predicts possible shape deterioration due to uneven material flow through the bearing zone and helps to equalise it by means of optimisation of the bearing design, chamber and feeding channels. The locations of welding zones in the die are clearly predicted. It allows to modify the die design for better welding conditions and to provide optimal location of welding seams in the product. Die stress analysis shows the ways to extend the tool life by means of reducing of fatigue failure and selecting proper die materials as well as to correct the influence of the die deformation on the material flow. The described model is implemented in an especially dedicated program QForm-Extrusion that effectively simulates the extrusion of hollow and solid profiles with very high elongation ratios. The experimental verification of the model is illustrated by model and industrial experiments as well as by series of case studies performed in production environment.