Modeling Friction in HyperXtrude for Hot Forward Extrusion Simulation of EN AW 6060 and EN AW 6082 Alloys

Abstract

In this work, different friction models available in HyperXtrude had been investigated in the context of hot forward extrusion simulation of aluminum alloys. Extrusion trials were carried out for EN AW 6060 and EN AW 6082 at different temperatures and ram speeds. The extrusion forces as well as material temperatures near the exit of the die were recorded and used for the validation of the simulations. FE-simulations of each extrusion trial were carried out in HyperXtrude. Initially, friction models were calibrated for only two extrusion trials. Then, these calibrated friction models were used to simulate the extrusion trials with different process parameters. Reasonably good agreements were observed between experiments and simulations in terms of extrusion forces. However, the simulations overpredicted the material temperature by almost up to 40 °C for extrusion trials with high ram speed.