FEM Codes Benchmark for Aluminum Extrusion Process Analysis”

The paper presents an overview on the two previous editions of the benchmark conferences (2007 and 2009) and compares the accuracy of the different FEM codes in predicting critical process outputs. In the 2007 edition four L-shaped profiles were produced under different profile thickness and pockets shape thus realizing different final profiles length. In the 2009 edition a multihole dies producing two overlapped U-shape profile was used: the two die openings were differently designed in order to realize different die deflection (fully supported and partially supported tongues). Profile lengths, die and profile temperatures, and process load were used as benchmarking parameters for FEM comparison moreover in the 2009 the particular design of the die allowed also the monitoring of tongues deflections during the extrusion stroke. The paper starts with a brief description of the experimental conditions, repetitions and main results, then a summary of the different FEM codes computational times and of the main outputs and their comparison with experimental results are presented. A detailed discussion for all output parameters is realized in order to understand potentials and limits of each code. Finally a discussion on future perspective for FE code application and designing guides is reported.