Role of die structures on metal flow balance in multi-output porthole extrusion of thin-walled profile

A novel multi-output porthole extrusion die for thin-walled aluminum alloy profile is introduced and its thermo-mechanical modeling for the analyses of metal flow and elasto-plastic deformation is developed. In order to explore the sources of undesirable deformations, two key deformation behaviors (non-uniform relative exit velocity of profile and mandrel deflection of extrusion die) which play considerable effects on the metal flow balance are analyzed based on the developed numerical model. Finally, the optimization design of the multi-output porthole extrusion die structure is performed for the improvement of extruded profile quality. (C) 2018 The Authors. Published by Elsevier B.V.