Finite element analysis of extrusion process using aluminum alloy

A coupled thermal-mechanical finite element analysis of axisymmetric direct extrusion process using aluminum alloy has been carried out using commercial software package ABAQUS (Standard). Effect of process parameters such as coefficient of friction, die angle and die profile radius on maximum nodal temperature, maximum contact pressure, deformation homogeneity are investigated in this paper. Heat generation due to plastic deformation and frictional heat generated between interacting surfaces of die and billet are considered in the analysis. It is found that coefficient of friction has significant effect on maximum nodal temperature while little influence on deformation homogeneity. It is also gathered that die angle has a considerable effect on deformation and on contact extrusion pressure. Besides, this it is also found that die profile radius has an appreciable influence on contact extrusion pressure. This study helps in selection of appropriate process parameters for proper designing of direct extrusion process.