TY - CONF

T1 - Coupled analysis of material flow and die deflection in direct aluminum extrusion

AU - Assaad, W.

AU - Geijselaers, Hubertus J.M.

PY - 2010

Y1 - 2010

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.

KW - IR-74115

M3 - Paper

ER -