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Numerical simulation of extrusion process of aluminum profile with large extrusion ratio

HUANG Guang-fa~1,LIN Gao-yong~(1,2),JIANG Jie~3, WANG Fang~3,YANG Li-bin~1,PENG Da-shu~1(1.School of Materials Science and Engineering,Central South University, Changsha 410083,China; 2.State Key Laboratory of Plastic Forming Simulation and Die Technology, Huazhong University of Science and Technology,Wuhan 430074,China; 3.Yunnan Mechanical Research and Design Institute,Kunming 650031,China)  
A new simulation system was developed by integrating the finite element method(FEM) and the finite volume method(FVM) based on the theories of large deformation elastic-plastic finite element method and finite volume method.To avoid time-consuming and obtain reasonable results in the simulation,the optimized geometry models were employed in the pre-processor.The forming of a complex thinwalled aluminum profile with large extrusion ratio λ=98.27 and 1mm in thickness,was successfully simulated in the new simulation system on the platform of MSC Superforge.The simulation results are agreeable to the general extrusion principles.The distributions of velocity field,effective stress field,effective strain field and temperature field during the extrusion process were discussed and the metal process was analyzed in details.The results indicate that the flow guide is effective in balancing the metal deforming during the profile extrusion process with large extrusion ratio.
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