Altair HyperXtrude 2025 Release Notes
Altair HyperXtrude is a suite of finite element solvers for simulating the following
manufacturing processes. These solutions have interfaces in Inspire; the HyperXtrude
solver is also called the Inspire Extrude Solver.
- Binder Jet Sintering
- Metal Extrusion
- Polymer Extrusion
- Quenching
- Calibration
- Metal Rolling
- Friction Stir Welding
- Resin Transfer Molding
Highlights
- Elastoplastic quenching warpage analysis
- Nose cone animation for transient nose cone analysis
Metal Extrusion
New Features
- Nose cone animation
- The nose cone emerging from the die is now animated in the bearing and profile 3D regions. This animation is restricted to ram acceleration time. This feature is supported in the transient nose cone and transient 1-cycle analyses. (SLVHXT-777)
- Tracking billet skin in multicycle analysis
- In a multicycle analysis, the billet skin material migrated into the non-billet regions is now retained in the previous cycle instead of reinitializing the skin data everywhere. This approach allows for simulation of the effect of accumulated skin material in the scrap prediction. (SLVHXT-769, SLVHXT-349)
Enhancements
- Parameter to control core heat transfer
- A new parameter is added to control the core heat transfer in the
mandrel/interior regions of the die. This factor can be set to one of
the following three values:
- -1 (Default)
- The solver picks what is appropriate for the model.
- 0
- The core heat transfer control is off. No special rules are used in the core region. This is more appropriate for solid-profile dies.
- 1
- The core heat transfer control is on. This is more appropriate for hollow-profile dies that have portholes.
Resolved Issues
- Improved accuracy in gap thickness calculation via DCT algorithm
- The predicted nose cone depends on the bearing friction, which in turn depends on the thickness computation. In this release, the DCT algorithm is improved to avoid failures under some conditions. With this improvement, thickness computation and nose cone prediction improved for some simulations. (SLVHXT-788)
- Flow in the bearing region does not conform to the bearing curve
- There was a bug related to the profile shape factor usage in the bearing region’s flow computations. With this issue now fixed, the flow in the bearing region is improved. This has resulted in an improved profile nose cone for many simulations. (SLVHXT-773, SLVHXT-634, SLVHXT-736, SLVHXT-719, SLVHXT-755)
- Error in writing temperature result in the particle trace CSV file
- The temperature is now written for the particles in the CSV file. (SLVHXT-774)
- Stat file does not have delimiter specified correctly
- This issue was noticed for simulations having multiple exits. The comma is now printed after the exit temperature, therefore for multi-hole models, the data after that no longer appears as a single column. (SLVHXT-775)
Quenching
New Features
- Elastoplastic warpage analysis
- The quenching simulation now supports elastoplastic analysis. The greatest benefit of this analysis is the prediction of plastic strain that remains in the quenched profile at the end of the simulation. The solver uses the non-uniform temperature distribution during the quenching process to compute the thermal residual stress. In the final step, the profile is cooled to room temperature with minimal constraints using the inertia relief conditions, which retains only the warpage deformation. (SLVHXT-772)
- Residual stress in the profile after quenching
- The solver computes and uses the thermal stresses for warpage prediction. When the elastoplastic analysis is performed, the stresses are in the final step, which has minimal constraints and no external loading conditions and so can be considered as the residual stresses that cause the predicted warpage. (SLVHXT-716)
- Quenching animation control with distance function
- A distance function is implemented in the solver to improve the presentation of results correctly in Inspire. This helps ensure Inspire shows only the profile that has exited the die. (SLVHXT-777)