Plastic Flow Analysis in Hot Aluminum Extrusion of Asymmetric Parts

Abstract

In this study, a design guideline for the die cavity and die bearing length distribution is proposed during an extrusion process of an asymmetrical thin sheet, such as clips of cell-phones. The plastic flow pattern of the billet inside the die cavity is analyzed using a commercial finite element package “DEFORM 3D”. The Module of Die Stress Analysis in the finite element software “DEFORM 3D” is also used to simulate the stress, strain, and the displacement distributions of the die during extrusion of clips of cell-phones. The extrusion load, the stress and strain distributions of the die, the temperature distribution, and thickness distribution of the extruded product are investigated. Furthermore, hot extrusion experiments using A6061 as the specimen are executed. The experimental results of temperature, thickness distribution of the product, extrusion force, etc, are compared with the analytical values to verify the validity of the proposed die design guideline.