Title: Mathematical modelling and numerical simulation of direct extrusion process for different cross-section of dies

Authors: D.P. Jena

Addresses: Department of Industrial Design, National Institute of Technology Rourkela, 769008, India

Abstract: The present research derives the analytical solutions for direct extrusion for different cross-sections of dies. Additionally, to exterminate the limitation and complexity of analytical solution for complex shapes, and validation of analytically calculated results, the finite element-based simulation is demonstrated. First, the tensile and compressive strength for AA6063-T7 and AA6061 are calculated using simulations and verified with experimental measurements. Then, the simulation of direct extrusion is conducted and authenticated with experimental measurements. Finally, with convinced assumptions, the analytical model for different dies such as elliptical, square, and rectangle shapes are derived. It is shown that the calculated results from simulations agree to analytically calculated results with less than 5% error for different coefficient of frictions and different extrusion ratios.

Keywords: tensile test; compressive test; analytical modelling; direct extrusion process; finite element analysis; FEA.

DOI: 10.1504/IJMTM.2023.131023

International Journal of Manufacturing Technology and Management, 2023 Vol.37 No.1, pp.49 - 70

Accepted: 19 Jan 2021
Published online: 19 May 2023 *