Tutorial: Hollow Profile Extrusion

Tutorial Level: Beginner Set up and complete a hollow profile extrusion analysis and post-process the data.

Model contains madrel and die cap. Two hollow profiles are being extruded through this die assembly. Data files are available in the tutorial_models folder in the installation directory in Program Files\Altair\2025\InspireExtrudeMetal2025\tutorial_models\extrudemetal\tutorial-2\.

Note: Units are set to MPA (mm t N s) by default.

Import and Orient Die Solids

  1. Click Start and search for Inspire Extrude, or double-click and launch Inspire Extrude from the shortcut on your desktop.
  2. Click File > New to start a new session.
  3. Drag the model files, SciBench2011_die.x_t and SciBench2011_mand.x_t, into Inspire Extrude to import the die geometry.
  4. Click the Extrusion ribbon.
  5. Click the Orient tool to position the model.

    The die should be oriented such that the profile is coming out in the +Z direction.
    The center of the die face touching the billet is at X=0, Y=0, and Z=0

  6. Click the exit face of the die assembly to orient the model.


The orient context is enabled.

Extract Flow Volume

  1. Click the Flow Volume icon to extract flow volume inside of the die cavity.
  2. Click and hold left mouse button while you drag a box around all the die solids as shown.
  3. Release left mouse button to extract flow volume automatically.

Combine Flow Volume

  1. Hold CTRL and click on each flow solid as shown.
  2. Right-click on either selected solid and click Organize As > FlowVolume.

The two separate Flow Volume pieces are now part of the same FlowVolume piece.

Extract Bearing Region

  1. Zoom in to the region where bearing starts.
  2. Click the Bearing icon.


  3. Select the bearing start surface.


Program will automatically scan the geometry and discard the relief region and create bearing and profile solids.
Note: Once the bearing is extracted, you will be prompted to specify lengths for bearing and profile solids. You can keep the default value and proceed. Profile region is 3 to 5 times the bearing region.


Note: Profile is included in the model to capture how the profile deflects.

Organize Flow Volume

  1. Click the Organize Volumes based on Length Icon.

  2. A micro dialogue will pop up, where you must enter the following measurements:
  3. Press OK to close the window.
Inspire Extrude will cut the flow volume length based on the component lengths specified and organize them into their respective components automatically.

Create the Billet

  1. Click the Create Billet icon.
  2. In the small window that pops up, specify the below billet dimensions and press Enter.

    Note: Leave the Skin thickness checkbox unchecked.
  3. Press Esc to exit this panel.
The billet is created according to the specified dimensions. The computation begins with an upset billet, thus the billet is created with upset length based on container diameter.

Select the Material

  1. Click the Materials icon.
  2. Drill down to the respective alloy Aluminum_Alloys > 6000_Series > AA6063



  3. Right-click on the alloy name and click Select.
    The chosen alloy is now added to the Selected Materials window.
    Note: To deselect a material in the Selected Materials window, right-click and click Deselect.

  4. Click OK to close the Material Database.
  5. Click File > Save As to save the model at the desired location.
    Note: It is recommended that you always save the model file in a newly created folder to avoid conflict with older/existing model files.

Specify Process Parameters and Simulate

  1. Click theSubmit job for analysis icon to run the simulation.
  2. In the Analysis Parameters window that pops up, enter values as shown.

  3. Click the Run button.
On successful launch of the run, you can monitor the status of the simulation.
Status after submitting the job


Status after meshing is completed


Status when job is running in the solver


View Simulation Results

Click the various Result Types to change the analysis output. This data provides a detailed understanding of how material deforms and flows during extrusion. Using this data, we can detect flow imbalances at the die exit. Understanding the material flow in die regions such as portholes and pockets helps in redesigning to improve the performance of the die.
  1. Select Pressure under Result Types.

    The pressure at the ram end provides the extrusion force required to push the billet. This data also provides information on the resulting extrusion loads on the die surfaces, and can be used to predict tool deflection.


  2. Select Temperature under Result Types.
    Understanding temperature distribution is the key to successful extrusion. Flow stress of a material is a strong function of temperature and strain rate. In addition, key material characteristics such as grain size depend on temperature. Temperature data is used to determine where excessive heating occurs in the die due to stress work. Temperature distribution in the profile region is used to determine the surface quality and other material characteristics.
    In the case of hollow profiles, the solver calculates seam weld location and strength.