Numerical analysis and geometric optimisation of tools for ceramic mass extrusion

Marek Hawryluk*¹ , Jan Marzec¹ , Konrad Perzyński² , Łukasz Dudkiewicz¹ , Bartosz Jóźwiak¹ , Marek Wiergowski³ , Magdalena Lemiech⁴ , Jacek Michalczyk⁵

¹Wroclaw University of Science and Technology, ul. Wybrzeże Stanisława Wyspiańskiego 27, 50-370 Wrocław, Poland.

²AGH University of Krakow, Al. Adama Mickiewicza 30, 30-059 Krakow, Poland.

³GKN Driveline Polska sp. z o.o., ul. Krzywoustego 31G, 56-400 Oleśnica, Poland.

⁴Global Point sp. z o.o., sp. komandytowa, ul. Rozwoju 3, 55-040 Biskupice Podgórne, Poland.

⁵Częstochowa University of Technology, Al. Armii Krajowej 19, 42-200 Częstochowa, Poland.

DOI:

https://doi.org/10.7494/cmms.2026.2.1054

Abstract:

The article presents a numerical analysis of the ceramic mass extrusion process and an assessment of the influence of the geometry of the tools’ inlet zone on their loading and service life. The rheological properties of the investigated ceramic mass were determined based on compression tests, while the friction conditions were evaluated using ring compression tests, yielding a friction coefficient of μ = 0.2. The extrusion process was modelled using the Abaqus 2024 software and the mesh-free smoothed particle hydrodynamics (SPH) method. The analysis considered the baseline geometry as well as variants incorporating fillets at the working edge with radii of R = 2.5 and 5 mm. The simulation results demonstrated a reduction in local stress concentrations and a more favourable stress distribution for the variant with a radius of R = 5 mm and an angle of 12°, which was selected for industrial verification. Measurements of tool wear after 170 h of operation, performed using 3D scanning, confirmed that the location of the maximum wear corresponded to the areas of elevated stresses identified by the model. The application of the modified geometry reduced the maximum material loss in the working-edge region from more than 1.67 mm to 1.30 mm, corresponding to a reduction in wear of more than 20%.

Cite as:

Hawryluk, M., Marzec, J., Perzyński, K., Dudkiewicz, Ł., Jóźwiak, B., Wiergowski, M., Lemiech, M., & Michalczyk, J. (2026). Numerical analysis and geometric optimisation of tools for ceramic mass extrusion. Computer Methods in Materials Science, 26(2), XX-XX. https://doi.org/10.7494/cmms.2026.2.1054

Article (PDF):

Accepted manuscript: the final PDF will be available soon.

Keywords:

ceramic mass, extrusion, SPH modelling, geometry optimisation, tool wear

Publication dates:

Received: 20.08.2026, Accepted: 07.10.2026, Published: XX.11.2026

Publication type:

Original scientific paper

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