Isothermal extrusion speed curve design for porthole die of hollow aluminium profile based on PID algorithm and finite element simulations

Abstract

The isothermal extrusion process of hollow aluminium profile was investigated using incremental proportional–integral–derivative (PID) control algorithm and finite element simulations. The range of extrusion speed was determined by considering the maximum extrusion load and production efficiency. By taking the optimal solution temperature of the secondary phase as the target temperature, the extrusion speed–stroke curve for realizing the isothermal extrusion of the aluminium profile was obtained. Results show that in the traditional constant extrusion speed process, the average temperature of the cross-section of the aluminium profile at the die exit rapidly increases and then slowly rises with the increase in ram displacement. As the extrusion speed increases, the temperature difference at the die exit of the profile along the extrusion direction increases. The exit temperature difference between the front and back ends of the extrudate along the extrusion direction obtained by adopting isothermal extrusion is about 6.9 °C. Furthermore, the heat generated by plastic deformation and friction during extrusion is balanced with the heat transfer from the workpiece to the container, porthole die and external environment.