Abstract
In extrusion industry, optimization of die design plays a critical role in contributing to the quality of the extruded profile as well as tooling life. This study addresses the fact that most dies today are typically designed following a trial and error approach based on empirical knowledge of the designer, which inevitably results in increasing scrap rate and cost. The purpose is to understand the effects of geometry on the performance of a porthole die in order to improve the life of tooling and quality of the final extruded shape using finite element based simulations. In this work, a finite element (FE) model is developed to simulate the extrusion of a commercial grade aluminum alloy to produce a condenser tube used for cooling systems. Using the Update Lagrange FE analysis first, the tooling components of the modular die are assumed to be rigid in order to achieve the right friction coefficients to validate the experimental data collected during trail runs of the modular die. Next, DOE is used to identify the relative influence of the three main parameters that control the geometry of the mandrel. For each parametric set, a steady-state FE analysis is run to predict the maximum weld pressure between the mandrel port webs. The insight gained from these simulations is used to optimize the mandrel geometry.
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