Analysis and Design of Industrial Hot Extrusion Process through Square Dies for Manufacturing Complicated Al Alloy Profiles

Abstract

In the analysis and design of hot square die extrusion processes, non-steady state analysis together with temperature analysis is recommended. In the present work, non-steady state analysis are carried out for hot square die extrusion of some typical industrial profiles by using the rigid-viscoplastic arbitrary Lagrangian-Eulerian(ALE) finite element method. Since flow guide and die lands play important roles in controlling the metal flow in the industrial practice, the related analyses are carried out and the effects of die land and flow guide are discussed. In order to estimate the variation of die land length, a scheme has been developed. The scheme is applied to extrusion of L-section without any axis of symmetry. The calculated configuration of die land is compared with the industrial design. As an effective tool for prediction of die wear, a wear map in introduced and demonstrated through the examples.