A Novel Analytical Formula for Charge Weld Extend Prediction

In the continuous extrusion process, the scrap derived from the charge welds defect is a relevant cost that shall be limited. In addition, the risk of selling profile sections containing the charge and then with low mechanical properties needsto be avoided in case of structural applications. In recent years, the potentiality in the use of numerical tools has been proved for the prediction of the charge welds extent. However, the required simulations are time-dependent, leading for complex profiles, to many hours of computation. It then emerges the interest for a faster analytical approach able to accurately predict the charge weld extend. The aim of the work is to propose a novel analytical formula that overcomes the limitations of those available in literature. Many experimental and numerical data collected on industrial profiles were analyzed to calibrate and validate the novel formula.