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Development of a System for Ultrasonic Die Oscillations during Extrusion of Aluminum Hollow Profiles

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Abstract:

High friction in aluminum hollow profile extrusion limits material flow, process stability, and productivity. Ultrasonic vibration offers a promising approach to reduce friction, yet its application to industrial porthole dies is still insufficiently explored. This study presents the development and investigation of an ultrasonic die sonication system for aluminum extrusion. Finite element extrusion simulations demonstrate that reduced friction leads to lower extrusion forces, decreased profile exit temperatures, and improved material flow. A modified porthole die enabling ultrasonic excitation at multiple positions was designed accordingly. The vibrational behavior of the die was analyzed using three-dimensional modal and harmonic finite element simulations. Suitable excitation frequencies between 18.5 and 23 kHz were identified and experimentally validated by laser vibrometry, confirming effective transmission of ultrasonic vibrations into the die. The simulation results demonstrate the feasibility of ultrasonic die oscillation for aluminum hollow profile extrusion and provide a solid basis for forthcoming extrusion trials and further process optimization. The system was implemented, approved, and is now available for upcoming experimental trials.

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Periodical:

Key Engineering Materials (Volume 1048)

Pages:

109-119

DOI:

https://doi.org/10.4028/p-3FoSSm

Citation:

Cite this paper

Online since:

April 2026

Authors:

Tamara Thomas*, Maik Negendank, Nico Laengst, Verena Merklinger, Joachim Maier, Soeren Mueller

Keywords:

Aluminum Extrusion, FEM, High-Frequency Die Oscillation, Hollow Profile

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Creative Commons CC BY 4.0

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* - Corresponding Author

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