Numerical simulation of the extrusion process with different FEM code approaches: analysis of thermal field, profile speed, defects evolution, and microstructure of hollow tubes

Over the years, the utilization of FEM numerical simulation has become a valuable tool for both die makers and extruders. To assess the evolution of FEM codes in terms of problemsolving potentiality, accuracy, as well as reduction of computational time, the 'ICEB - International Conference on Extrusion and Benchmark' conference series was established. The participants, who are unaware of the experimental outputs in advance, share with the organizers their numerical results to be compared with the actual experimental data. Analysis and discussion of the results during the conference allows users to check if their simulation settings are adequate to replicate the problems, and software house to verify the sensitivity of their solving methods. For the ICEB 2023, hollow tube-shaped profiles in AA6082 were extruded by varying the nitrogen flow rate and the quenching conditions. The experimental-numerical comparison was assessed in terms of press load, profile speeds, profile and die temperatures, defects evolution, nitrogen cooling efficiency, and the profiles’ microstructure.