DEFORM-Based Analysis and Discussion of Early Failure in Warm Extrusion Dies

Abstract

In this study, the true working conditions of a warm extrusion die was simulated using DEFORM-3D software; images of the die’s temperature, stress, and wear distributions were obtained, the amount of wear of the die cavity were calculated, and the wear depth curves were drawn for each test point on the basis of this simulation. A production analysis along with the simulation revealed the main forms of early failure for the warm extrusion mold to be cracking failure, collapsing failure, and wear failure. Through data analysis, the areas of the die that cracked easily or showed heavy wear were identified. The steps required to prevent early failure are proposed in this article.