Numerical Simulation and Die Optimal Design of a Complex Section Thin-Walled Aluminum Profile Extrusion

The most important way to improve the quality of aluminum extrudates is to assure the material flow through die exit with the same velocity. Usually, aluminum profile extrusion is a very complex process of metal flow, which is mainly dependent on the level of the die design. Yet current design of extrusion die is primarily based on the trial-and-error method, which is to a large extent is determined by the experience of the die designers. In this research, a numerical model was developed to simulate the extrusion process for a complex section thin-walled aluminum profile with HyperXtrude. According to the non-uniformity of metal flow with the original die, several modifications, such as drainage channels, baffle plates and local bearing length, were performed to optimize the die structure. Finally, an optimal die design with more uniform flow velocity was achieved. The research results showed that the numerical model developed in this paper was effective for aluminum profile extrusion die optimization.