Modelling highly deformable metal extrusion using SPH

Abstract

Computational modelling is often used to reduce trial extrusions through accurate defect prediction. Traditionally, metal extrusion is modelled using mesh based finite element methods. However, large plastic deformations can lead to heavy re-meshing and numerical diffusion. Here we use the mesh-less smoothed particle hydrodynamics method since it allows simulation of large deformations without re-meshing and the tracking of history dependent properties such as plastic strain making it suitable for defect prediction. The variation in plastic strain and deformation for aluminium alloy in a cylindrical 3D geometry with extrusion ratio and die angle is evaluated. The extrusion process is found to have three distinct phases consisting of an initial sharp rise in extrusion force, a steady phase requiring constant force and terminating in a sharp decline in force as metal is completely extruded. Deformation and plastic strain increased significantly with extrusion ratio but only moderately with die angle. Extrusion force increased by 150 % as the extrusion ratio increased from 2:1 to 4:1 but had only a marginal change with die angle. A low strain zone in the centre of the extruded product was found to be a function of extrusion ratio but was persistent and did not vary with die angle. Simulation of a complex 3D building industry component showed large variations in plastic strain along the length of the product at two scales. These were due to change in metal behaviour as extrusion progressed from phase 1 to phase 2. A stagnation zone at the back of the die was predicted that could lead to the “funnel” or “pipe” defect.