FEM-Assisted Design of a Multi-Hole Pocket Die to Extrude U-Shaped Aluminum Profiles with Different Wall Thicknesses
Wide, thin-wall profiles exiting simultaneously from a multi-hole die during aluminum extrusion tend to have different velocities and deflect from the straight line. The pockets in front of the die orifices are often used to balance the metal flow and equalize the velocities. In practice, the effect of a pocket die design on metal flow becomes known, only after the die is manufactured and a trial extrusion run is completed. The present research was intended to demonstrate the feasibility of using FEM simulation to predict metal flow, thereby reducing or hopefully eliminating trial extrusion runs. The extrusion of U-shaped profiles with different wall thicknesses through a multi-hole pocket was taken as an example to show the scope of adjusting the die pocket to regulate metal flow. The effect of pocket shape on metal flow was evaluated. It is clear that 3D FEM simulation can indeed be effectively used to optimize die design, before the die design is finalized.
A. Erman Tekkaya and Nooman Ben Khalifa
G. Fang et al., "FEM-Assisted Design of a Multi-Hole Pocket Die to Extrude U-Shaped Aluminum Profiles with Different Wall Thicknesses", Key Engineering Materials, Vol. 424, pp. 213-220, 2010