Cairo University Faculty of Engineering

Metal Forming Finite Element Analysis of Extrusion

4th year Mechanical Design and Production Department

Objectives: 1- To study the finite element modeling of Extrusion process using available FE software package. 2- To understand the main advantages of using finite element simulation of Extrusion process.

Introduction: Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections and work materials that are brittle, because the material only encounters compressive and shear stresses. It also forms finished parts with an excellent surface finish.

Problem description: An Aluminum bar has an initial radius of 100 mm and is 300 mm long. In this particular problem the radius of an aluminum cylindrical bar is reduced 33% by an extrusion process. Figure below shows half of the cross-section of the bar, modeled with first-order axisymmetric elements. The generation of heat due to plastic dissipation inside the bar and the frictional heat generation at the workpiece/die interface are considered.

Required: The student is requested to follow carefully the demonstration session on the finite element modeling and simulation of the given problem. The student should present a report including the following: 1- Discuss the main steps followed in the finite element modeling of the Extrusion process. 2- Discuss the main advantages and limitations for finite element analysis in bulk deformation processes. 3- Define the main terminologies discussed in the session such as (meshing- step time etc,) 4- From the solved example on the tutorial : Draw force-displacement diagram Draw the deformed shape and illustrate the stress distribution on it Draw Temperature-time diagram for selected node 5- Search the internet for the most common FE programs used in bulk deformation processes (such as extrusion, rolling,..etc,) 6- References must be given at the end of report, together with a hard and soft copy of the internet search