Submitting a Job

Define and run an analyis using the Run Analysis tool.

The model setup should be completed before submitting job for analysis. Save the model in a new folder with the desired project name. Analysis will be performed in this folder based on user preference under Run Options.

  1. Click on the Analysis tool in the Run group.
  2. In the Analysis Parameters dialog, define parameters accordingly.
  3. Click Run to submit the job.
    The status of the run is displayed.
  4. Click Export to complete the pre-processing.
    The process stops after the data decks for the solver are generated.

Analysis Parameters Settings

Project Name
The data deck is written with "name" as a prefix. It is written in the same folder where the model is saved. Avoid using special characters as files will be created using this name.
Ram Speed
Ram velocity. The speed of the punch (also referred to as ram or dummy block).
Extrusion Ratio
The ratio of the cross-sectional area of the billet over the cross-sectional area of the extruded profile.
Profile Speed
The speed at which the extruded material exits the die.
Billet Preheat
Used as the initial condition for the analysis for transient runs, and as initial guess for steady state analysis.
Die Temperature
Used to specify the heat transfer condition at the workpiece and die interface.
Container Temperature
Used to specify the heat transfer condition at the container and billet interface.
Use Bearing Reference Surfaces
Check this box to include bearing reference surfaces. Specify Max Choke Angle to set the bound for the maximum choke angle determined from the reference surface.
Mesh Size
Medium is the preferred option. If the model has many fine features, selecting fine is recommended. If it is a simple model, coarse option can be used. To start from existing mesh, click on Existing and select the mesh file. To specify mesh size by part, click on User-defined, then click the Mesh size tab and adjust default mesh sizes.
Extrusion Type
Direct. Dummy block moves at the ram speed.
Indirect. Both dummy block and container move at ram speed.
Analysis Type
Steady State. Default selection.
Transient. Automatically selected when the billet is created with skin. A typical transient analysis take around five times the computational time of steady state analysis. Some of the uses are for analysis of charge weld, back end defects, tapered heating, starter billets, full cycle, and multi cycle analysis.
Transient Nose Cone. Enables nose cone analysis for billets with taper-heated billets (non-uniform billet preheat). This allows for a more accurate simulation of how the profile initially forms as the material exits the die.
Note: This feature is focused on nose cone visualization and is not a die-filling simulation.
Bearing Optimization. Select this option to include bearing optimization in the simulation. Bearing Optimization is an automated analysis that adjusts the bearing lengths in the die to ensure material exits uniformly across the profile. This helps ensure better flow balance, improved part quality, and reduced trial-and-error in die design. When enabled, the solver iteratively modifies the bearing lengths to minimize velocity variation at the profile exit.
You can fine-tune the optimization behavior through the Advanced tab:
  • Max Optimization Iterations - Sets the maximum number of optimization iterations. The default is 20 iterations.
  • Optimization Tolerance - Controls the convergence criteria for acceptable velocity uniformity. The default is 5%.

Details of the optimization can be found in OptBearingStatistics.csv in the bearing-optimization-files folder within the run folder, as well as in the Bearing Correction section of the .out file.

Coupled Analysis
No: Runs the extrusion simulation without any coupled structural or thermal analysis.
Solver: Enables coupled analysis. When selected, you must choose one of the solvers (OptiStruct or HX) depending on your analysis goal. Ensure that the tool geometry and model setup (material, boundary conditions, etc.) are properly defined to perform coupling.
Solver options when coupled analysis is turned on:
  • OptiStruct (OS): Performs a mechanical deformation analysis of the tooling (e.g., die, mandrel).

    The purpose of coupling with OptiStruct is to improve the accuracy of nose cone prediction and flow distribution by incorporating the effect of die opening due to tool deflection.

    Tool deformation can be simulated using:

    • Elastic: Linear elastic deformation only.
    • Elasto-Plastic: Accounts for plastic yielding in the tool under high stress.
      Note: If you select Elasto-Plastic, Inspire Extrude automatically performs a two-step tool deflection analysis. When the pressure in the extrusion simulation reaches the specified convergence tolerance, the solver writes the loads on the contact surfaces between the workpiece and the tool. These loads are used by OptiStruct to perform the tool stress analysis and compute tool deformation. The modulus of the tool varies significantly with temperature. To consider this, the coupled solution has been enhanced to perform a heat transfer step subcase before performing the stress analysis. To enable this, the solver writes temperature on the tool contact surfaces in addition to pressure. This increases the accuracy of the stress analysis solution
  • HyperXtrude (HX): Performs a conjugate heat transfer (CHT) analysis between the workpiece and the tooling. This mode helps assess the thermal stability of the extrusion process.
Optionally, you can choose to Ignore Thermal Stresses. This option is applicable only when using OptiStruct as the coupled solver. When enabled, thermal expansion effects are excluded from the mechanical stress calculation. Temperature still influences material properties, but thermal-induced deformation or stress is not included. This is useful when you want to focus on mechanical loading and exclude stresses caused purely by temperature gradients.
Advanced Tab
The Advanced tab provides access to expert-level options for the solver.
Specify User Defined Functions: Use this section to incorporate custom material models or grain prediction models via user-defined dynamic link libraries (DLLs). For more information on integrating user-defined functions, refer to the advanced training packet.
  • Select DLL: Provide the path to the DLL file. Sample DLLs are available at: <Installation Folder>\Altair\2026\hwsolvers\hx\lib\win64.
  • Select Function: Choose the specific function within the DLL to use.
  • Select Type: Specify whether the DLL is for a Material or Grain Size.
User Commands - Before Loading GRF: Use this field to override the default solver parameters before loading the GRF file. Enter pset parameters directly in the text box.
User Commands - After Loading GRF: Use this field to override the default solver parameters after loading the GRF file. Enter pset parameters directly in the text box.
For a list of supported pset variables, refer to What are Key pset Solver Variables?.

Advanced Mesh Controls

Under Mesh Size, click Advanced Mesh Controls to open the Mesh Controls tab.

The default option under Mesh Type is Automatic. Additional options are detailed below.

Start from Existing Mesh

Start from an existing mesh in Advanced Mesh Controls.

  1. In the Mesh Controls tab, click Existing under Mesh Type options.
  2. Enter the path to the mesh file or browse to it.
    Note:

    Supported data formats:

    *.grf, *.bdf, and *.fem

    Specifications:

    1. The length unit of mesh must be the same as the user unit.
    2. The meshed part name should be the same as the solid part name, with optional suffix "3D". For example, if the solid part name is DiePlate, then choices for meshed part names would be DiePlate3D or DiePlate.
    3. In the case of Portholes or WeldChamber, the meshed part names have additional choices:
      Solid Part Name Meshed Part Name
      Portholes Portholes3D, Portholes_WC3D
      WeldChamber WeldChamber3D, WC3D, WeldChamber, WC
    4. In the case of a hollow die, if both Portholes and WeldChamber exist, then mesh must be in separate components.
  3. Click Run to start the job.

User-Defined Mesh Controls

Define mesh size controls by part.

Under Mesh Type, click User-Defined to open the Mesh Size Controls table.

The table lists each part of the model, its type, volume, and surface. You can edit the volume value for each part.

Profile Mesh Controls

Define profile and bearing settings for the mesh.

Select the Profile Mesh Controls check box to show the following settings:
  • Biasing Default: Select either Inspire or HyperMesh to set the default values for Num Layers Bearing and Num Layers Profile.
  • Num Layers Bearing: Enter a value for the number of mesh layers across the bearing. A higher number of layers results in a finer, more detailed mesh, but at the result of more computation.
  • Biasing Intensity: Set the slider to one of three levels to determine how the mesh is distributed along the bearing. The following three fields are automatically adjusted based on this setting. At the lowest level, the Bearing First and Last Layer Sizes are the same.
  • Bearing First Layer Size: Adjusted automatically based on Num Layers Bearing and Biasing Intensity.
  • Bearing Last Layer Size: Adjusted automatically based on Num Layers Bearing and Biasing Intensity.
  • Num Layers Profile: The number of mesh layers across the profile. This value is automatically adjusted based on the Num Layers Bearing and Biasing Intensity, but can also be edited.