Case studies on virtual extrusion of aluminium alloys in real size

Two case studies were conducted to illustrate the capabilities of the state-of-the-art computer simulation technology applied to the aluminium extrusion process and demonstrate the usefulness of virtual extrusion in real size to the die designer and extrusion process engineer alike. A deform 3D software package was used for virtual extrusion in real size to manufacture a hollow profile through a porthole die (case I) and two precision solid profiles through a two-hole multi-step pocket die (case II). Temperature, stress and velocity distributions were revealed. In case I, the filling of the ports, welding in the welding chamber and forming of the hollow profile were visualised. The quality of the longitudinal welds along the hollow profile length was assessed. In case II, the deflection of two solid profiles from the centreline to different extents was predicted, thereby providing the guidelines for die design modification. The modified die indeed performed better.