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).
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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.",
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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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KW - Static condensation

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T3 - AIP conference proceedings

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EP - 500

BT - International Conference on Advances in Materials and Processing Technologies (AMPT2010)

A2 - Chinesta, Francisco

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A2 - El Mansori, Mohamed

PB - American Institute of Physics

ER -

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