Coupled Analysis of Material Flow and Die Deflection in Direct Aluminum Extrusion

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    Abstract

    The design of extrusion dies depends on the experience of the designer. After the die has been manufactured, it is tested during an extrusion trial and machined several times until it works properly. The die is designed by a trial and error method which is an expensive process in terms of time and the amount of scrap. In order to decrease the time and the amount of scrap, research is going on to replace the trial pressing with finite element simulations. The goal of these simulations is to predict the material flow through the die. In these simulations, it is required to calculate the material flow and the tool deformation simultaneously. Solving the system of equations concerning the material flow and the tool deformation becomes more difficult with increasing the complexity of the die. For example the total number of degrees of freedom can reach a value of 500,000 for a flat die. Therefore, actions must be taken to solve the material flow and the tool deformation simultaneously and faster. This paper describes the calculation of a flat die deformation used in the production of a U‐shape profile with a coupled method. In this calculation an Arbitrary Lagrangian Eulerian and Updated Lagrangian formulation are applied for the aluminum and the tool finite element models respectively. In addition, for decreasing the total number of degrees of freedom, the stiffness matrix of the tool is condensed to the contact nodes between the aluminum and the tool finite element models. Finally, the numerical results are compared with experiment results in terms of extrusion force and the angular deflection of the tongue.
    Original languageEnglish
    Title of host publicationInternational Conference on Advances in Materials and Processing Technologies (AMPT2010)
    EditorsFrancisco Chinesta, Yvan Chastel, Mohamed El Mansori
    PublisherAmerican Institute of Physics
    Pages495-500
    ISBN (Print)978-0-7354-0871-5
    DOIs
    Publication statusPublished - 24 Oct 2010
    EventInternational Conference on Advances in Materials and Processing Technologies, AMPT 2010 - Paris, France
    Duration: 24 Oct 201027 Oct 2010

    Publication series

    NameAIP conference proceedings
    PublisherAmerican Institute of Physics
    Number1
    Volume1315
    ISSN (Print)0094-243X
    ISSN (Electronic)1551-7616

    Conference

    ConferenceInternational Conference on Advances in Materials and Processing Technologies, AMPT 2010
    Abbreviated titleAMPT
    CountryFrance
    CityParis
    Period24/10/1027/10/10

    Fingerprint

    Extrusion
    Aluminum
    Extrusion dies
    Stiffness matrix
    Experiments

    Keywords

    • Aluminum extrusion
    • Die deflection
    • Coupled analysis
    • Static condensation

    Cite this

    Assaad, W., & Geijselaers, H. J. M. (2010). Coupled Analysis of Material Flow and Die Deflection in Direct Aluminum Extrusion. In F. Chinesta, Y. Chastel, & M. El Mansori (Eds.), International Conference on Advances in Materials and Processing Technologies (AMPT2010) (pp. 495-500). (AIP conference proceedings; Vol. 1315, No. 1). American Institute of Physics. https://doi.org/10.1063/1.3552494
    Assaad, W. ; Geijselaers, H.J.M. / Coupled Analysis of Material Flow and Die Deflection in Direct Aluminum Extrusion. International Conference on Advances in Materials and Processing Technologies (AMPT2010). editor / Francisco Chinesta ; Yvan Chastel ; Mohamed El Mansori. American Institute of Physics, 2010. pp. 495-500 (AIP conference proceedings; 1).
    @inproceedings{a5453fcf644a44239d2f303ede14257b,
    title = "Coupled Analysis of Material Flow and Die Deflection in Direct Aluminum Extrusion",
    abstract = "The design of extrusion dies depends on the experience of the designer. After the die has been manufactured, it is tested during an extrusion trial and machined several times until it works properly. The die is designed by a trial and error method which is an expensive process in terms of time and the amount of scrap. In order to decrease the time and the amount of scrap, research is going on to replace the trial pressing with finite element simulations. The goal of these simulations is to predict the material flow through the die. In these simulations, it is required to calculate the material flow and the tool deformation simultaneously. Solving the system of equations concerning the material flow and the tool deformation becomes more difficult with increasing the complexity of the die. For example the total number of degrees of freedom can reach a value of 500,000 for a flat die. Therefore, actions must be taken to solve the material flow and the tool deformation simultaneously and faster. This paper describes the calculation of a flat die deformation used in the production of a U‐shape profile with a coupled method. In this calculation an Arbitrary Lagrangian Eulerian and Updated Lagrangian formulation are applied for the aluminum and the tool finite element models respectively. In addition, for decreasing the total number of degrees of freedom, the stiffness matrix of the tool is condensed to the contact nodes between the aluminum and the tool finite element models. Finally, the numerical results are compared with experiment results in terms of extrusion force and the angular deflection of the tongue.",
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    Assaad, W & Geijselaers, HJM 2010, Coupled Analysis of Material Flow and Die Deflection in Direct Aluminum Extrusion. in F Chinesta, Y Chastel & M El Mansori (eds), International Conference on Advances in Materials and Processing Technologies (AMPT2010). AIP conference proceedings, no. 1, vol. 1315, American Institute of Physics, pp. 495-500, International Conference on Advances in Materials and Processing Technologies, AMPT 2010, Paris, France, 24/10/10. https://doi.org/10.1063/1.3552494

    Coupled Analysis of Material Flow and Die Deflection in Direct Aluminum Extrusion. / Assaad, W.; Geijselaers, H.J.M.

    International Conference on Advances in Materials and Processing Technologies (AMPT2010). ed. / Francisco Chinesta; Yvan Chastel; Mohamed El Mansori. American Institute of Physics, 2010. p. 495-500 (AIP conference proceedings; Vol. 1315, No. 1).

    Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review

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    N2 - The design of extrusion dies depends on the experience of the designer. After the die has been manufactured, it is tested during an extrusion trial and machined several times until it works properly. The die is designed by a trial and error method which is an expensive process in terms of time and the amount of scrap. In order to decrease the time and the amount of scrap, research is going on to replace the trial pressing with finite element simulations. The goal of these simulations is to predict the material flow through the die. In these simulations, it is required to calculate the material flow and the tool deformation simultaneously. Solving the system of equations concerning the material flow and the tool deformation becomes more difficult with increasing the complexity of the die. For example the total number of degrees of freedom can reach a value of 500,000 for a flat die. Therefore, actions must be taken to solve the material flow and the tool deformation simultaneously and faster. This paper describes the calculation of a flat die deformation used in the production of a U‐shape profile with a coupled method. In this calculation an Arbitrary Lagrangian Eulerian and Updated Lagrangian formulation are applied for the aluminum and the tool finite element models respectively. In addition, for decreasing the total number of degrees of freedom, the stiffness matrix of the tool is condensed to the contact nodes between the aluminum and the tool finite element models. Finally, the numerical results are compared with experiment results in terms of extrusion force and the angular deflection of the tongue.

    AB - The design of extrusion dies depends on the experience of the designer. After the die has been manufactured, it is tested during an extrusion trial and machined several times until it works properly. The die is designed by a trial and error method which is an expensive process in terms of time and the amount of scrap. In order to decrease the time and the amount of scrap, research is going on to replace the trial pressing with finite element simulations. The goal of these simulations is to predict the material flow through the die. In these simulations, it is required to calculate the material flow and the tool deformation simultaneously. Solving the system of equations concerning the material flow and the tool deformation becomes more difficult with increasing the complexity of the die. For example the total number of degrees of freedom can reach a value of 500,000 for a flat die. Therefore, actions must be taken to solve the material flow and the tool deformation simultaneously and faster. This paper describes the calculation of a flat die deformation used in the production of a U‐shape profile with a coupled method. In this calculation an Arbitrary Lagrangian Eulerian and Updated Lagrangian formulation are applied for the aluminum and the tool finite element models respectively. In addition, for decreasing the total number of degrees of freedom, the stiffness matrix of the tool is condensed to the contact nodes between the aluminum and the tool finite element models. Finally, the numerical results are compared with experiment results in terms of extrusion force and the angular deflection of the tongue.

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    Assaad W, Geijselaers HJM. Coupled Analysis of Material Flow and Die Deflection in Direct Aluminum Extrusion. In Chinesta F, Chastel Y, El Mansori M, editors, International Conference on Advances in Materials and Processing Technologies (AMPT2010). American Institute of Physics. 2010. p. 495-500. (AIP conference proceedings; 1). https://doi.org/10.1063/1.3552494