Numerical Simulation of Extrusion Process to Produce Complex Aluminum Profiles Using the ALE Approach

Although still having certain limitations, the numerical simulation technology has been increasingly applied to aid in optimizing the aluminum extrusion process and die design. In the present research, numerical simulations of the profiles extrusion process were performed, using the Finite Volume Method (FVM) and Finite Element Method (FEM) to make use of the individual merits of the Euler approach and Lagrange approach, respectively. The application of the simulation technology to produce large, complex profiles has, however, been quite limited. In order to solve the limited, numerical simulation of aluminum profiles with large and complicated cross-section in extrusion process was achieved using Arbitrary Lagrangian-Eulerian (ALE) approach, and non-uniform velocities at the die exit, leading to extrudate distortions, were predicted. Extrusion experiments proved that the die with the optimized design could circumvent the distortion problem. The numerical simulation technology can indeed be effectively used to reduce the number of die trials and offer the potential to realize zero die trial.