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Numerical simulation of aluminium extrusion with a Lagrangian FEM code

Aukrust T.

International Journal of Applied Mechanics and Engineering

2002

Vol. 7, no 1

157-171

The demands from the extrusion market are constantly evolving towards tighter geometrical tolerances. Simulation models that with sufficient accuracy describe the flow in the container and die, as well as the deflection after exit will therefore become important tools to understand how to avoid geometrical deflection and shape variations. From a simulation point of view the extrusion process is very challenging as it involves large reduction ratios, friction in the bearing channel region and complex deformations after the exit. While Eulerian codes are ideal for studies of flow and temperature evolution in the container and die, Lagrangian FEM codes are more suitable for simulation of friction in the bearing channel region and deformations after the outlet. In this work examples of simulations of extrusion in two and three dimensions with the Lagrangian FEM code Marc AutoForge are presented.