The application of numerical simulations to analyze the forward extrusion process along with the verification of results and tuning of the numerical model
Marek Hawryluk1
, Łukasz Dudkiewicz1,3, Jan Marzec1, Roger Tkocz4, Jacek Borowski5, Grzegorz Ficak6, Bartosz Jóźwiak7, Jacek Ziemba1,2
1Wroclaw University of Science and Technology, Department of Metal Forming, Welding and Metrology, Wroclaw, Poland.
2Center for Materials Science and Metal Forming, Wroclaw, Poland.
3Schraner Polska sp. z o.o., Łęczyca, Poland.
4MAHLE Behr Poland, Ostrów Wielkopolski, Poland.
5The Łukasiewicz Research Network – Poznań Institute of Technology, Poznań, Poland.
6GK FORGE sp. z o.o., Goleszów, Poland.
7GKN Driveline Polska sp. z o.o., Oleśnica, Poland.
DOI:
https://doi.org/10.7494/cmms.2025.2.1020
Abstract:
The paper presents the application of numerical simulations based on the Finite Element Method (FEM) for analyzing and optimizing the extrusion processes of aluminum and lead. These processes are efficient methods for manufacturing critical machine parts and metal components, ensuring excellent mechanical properties. A detailed analysis was conducted on the numerical modeling of the impact of die taper angles on strain distribution and forming forces during co-extrusion. The study found that a 45-degree angle provides optimal deformation conditions, minimizing extrusion forces and reducing the formation of dead zones compared to a 90-degree angle. Numerical simulations, supplemented by technological trials under semi-industrial conditions and image analysis involving the deformation of the coordinate grid, provided key insights into a material flow, strain distribution, and force parameters. The results emphasize the importance of validating numerical models with semi-industrial experiments to ensure accuracy and reliability, as assuming constant tribological conditions may not reflect actual process conditions, including the formation of dead zones for angles greater than 45°. It was only through a thorough analysis of the actual process and the introduction of variable friction coefficients for individual tools that a dead zone was achieved in the modelling. The findings from this research can serve as the foundation for further optimization and adaptation of technological processes, aiming to further enhance extrusion processes through the use of numerical simulations.
Cite as:
Hawryluk, M., Dudkiewicz, Ł., Marzec, J., Tkocz, R., Borowski, J., Ficak, G., Jóźwiak, B., & Ziemba, J. (2025). The application of numerical simulations to analyze the forward extrusion process along with the verification of results and tuning of the numerical model. Computer Methods in Materials Science, 25(2), 27–39. https://doi.org/10.7494/cmms.2025.2.1020
Article (PDF):
Keywords:
Forward extrusion process, FE modelling, Die draft angle, Dead zone, Aluminum and lead
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