Application of Physical Modeling with the Use of Soft Model Materials for the Analysis and Optimization of Metal Extrusion Processes

The study presents the concept of physical modeling together with the characterization of model materials as well as the possibilities of applying this type of physical simulation methods for the analysis, design, and optimization of industrial metal forming processes. The method provides the possibility to define the stress and deformation distribution, to estimate force parameters of the given process, and to localize dead zones and material flow errors. It can also be an alternative or supplementation to finite element modeling. The paper discusses the crucial similarity conditions between the physical model and the real process, which is necessary to transform the results into industrial processes. The developed database of soft model materials was also presented, on the basis of which a model material can be selected for almost any metallic materials. The paper also proposes a new description of the plastic similarity condition, which was verified by the example of two semi-industrial processes (backward and forward extrusion). The study demonstrates the attempt and the results of the influence of the matching of the model materials for three metallic materials, which, at ambient temperature, represent three main types of metal forming processes: hot (lead), warm (reinforced aluminum) and cold working (annealed aluminum). The obtained results showed great usefulness of the proposed condition of plastic similarity, because, in the case of a low value of the similarity coefficient (close to zero), both the flow method and the strength parameters obtained in physical modeling are very similar to the industrial process. On this basis, it can be assumed that by selecting the appropriate model material for the actual metallic material, you can quickly and easily optimize the industrial process with low financial outlays.