Experimental investigation and numerical analysis of the die deflection in aluminum extrusion

In order to assess the capability of numerical simulation in industrial hot aluminium extrusion, an extensive comparison was performed between data recorded during the experiment performed at 2009 ICEB conference and the process simulations performed by three FE codes: ALTAIR HyperXtrude®, COMSOL® Multiphysics and DEFORMTM 3D. In the experimental trials, two U-shaped profiles made of AA6082 alloy were extruded under monitored conditions: profiles exit temperature and velocity, extrusion load, die temperature and die deflection by means of an innovative laser-based method were continuously recorded during the trials. Numerical simulations were performed by means of the decoupled approach: at first, the material flow was computed with each code (DEFORM with an Updated Lagrangian approach, HYPERXTRUDE with an Arbitrarian Lagrangian Eulerian formulation, COMSOL based on a pure Eulerian approach); then the pressure was mapped and applied on the die face for a subsequent die stress analysis.