Abstract
The paper presents a detailed analysis of metal flow inside the extrusion dies and demonstrates the investigation of the formation of underfilling defects. The stress state in the defect zones has been analyzed by means of simulation based on the Eulerian approach. Based on this, it was found that the mean stress (hydrostatic pressure) is not the only parameter that has to be placed into the criterion to get reliable results. The author proposes a new dimensionless underfilling criterion adapted for Eulerian mesh. It is based on analysis of simulation results obtained by QForm Extrusion FEM software [1] and practical experiments for different types of profiles. This criterion has been approved, and critical values have been obtained using a number of industrial projects from different areas of application.
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