Abstract
A new concept has emerged recently in the design of complex 3D extrusion dies which vastly improves the product quality. In this paper, it has been demonstrated how an Advanced Die Design System (ADDSTM can be used in the so called streamlined extrusion die design, and how the die can be manufactured using computer aided facilities. ADDS utilises the concept of dynamic material modelling for optimizing the process design and streamline concept for obtaining the die profile. An indigenously developed computer program has been used to transfer the die profile to the Unigrophics II (UG II)2 system, which has been employed for processing the die design towards manufacturing of the die. Finally, NC programs were generated for use with a horizontal machining centre to machine copper electrodes which were subsequently used in EDM die sinking. With the linking of various CAE tools’, the methodology presented in this paper can be adopted to design and manufacture complex extrusion dies with high productivity.
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