Comprehensive Thermo-Mechanical Validation of Extrusion Simulation Cycle for Al 1100 Using HyperXtrude
Parkar, A. A, Bouvard, C., Marin, E., Horstemeyer, S., Horstemeyer, M., & Wang, P. (2011). Comprehensive Thermo-Mechanical Validation of Extrusion Simulation Cycle for Al 1100 Using HyperXtrude. In Subodh Das; Zhengdong Long; Tongguang Zhai (Eds.), TMS Proceedings CD-ROM: Aluminum Alloys: Fabrication, Characterization and Applications. San Diego, CA: TMS.
A laboratory-scale extrusion capability facilitates parametric
study of extrusion processes and we used HyperXtrude to simulate lab experiments performed with a flat-die. We validated the simulation results by comparing experimental and predicted load and temperature histories on tooling. ram velocity and billet temperature were the process parameters that were controlled. The simulations show a good agreement with experimental data. ‘Optimized’ values for friction and convection film-coefficient were used to reach the best fit. We discovered the peak load is predicted with good accuracy, but this trend is not sustained throughout the process duration and
there is as much as 20% deviation between the simulation and experimental results towards the end of the ram stroke. This work is aimed at benchmarking a commercial code for extrusion simulation for a range of profiles.