Comprehensive Thermo-Mechanical Validation of Extrusion Simulation Cycle for Al 1100 Using HyperXtrude
Parkar, A. A, Bouvard, C., Marin, E., Horstemeyer, S., Wang, P., & Horstemeyer, M. (2010). Comprehensive Thermo-Mechanical Validation of Extrusion Simulation Cycle for Al 1100 Using HyperXtrude. Aluminum Alloys: Fabrication, Characterization and Applications. 2011 TMS Annual Meeting & Exhibition (In Press).
A laboratory-scale extrusion capability facilitates parametric study of metal extrusion processes. Commercial simulation code, HyperXtrude, was used to simulate laboratory experiments performed using a flat-die. In the experiments, ram velocity and billet temperature were the process parameters that were controlled. Simulation model was validated by comparing the results with experimentally obtained load and temperature histories on tooling. The results of simulation and experiments were found to be in good agreement. ‘Optimized’ values for friction and convection film-coefficient were used to reach the best fit. The breakthrough load is predicted with good accuracy; however, the accuracy in load correlation is not sustained throughout the process duration as the predicted load trend deviates from experimental data towards the end of the ram stroke. The aim of this work is to benchmark a commercial extrusion simulation code for a range of profiles.