Tutorial: Hollow Profile Extrusion
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\2024\InspireExtrudeMetal2024.1\tutorial_models\extrudemetal\tutorial-2\.
Note: Units are set to MPA (mm t N s) by default.
Import and Orient Die Solids
- Click Start and search for Inspire Extrude, or double-click and launch Inspire Extrude from the shortcut on your desktop.
- Click to start a new session.
- Drag the model files, SciBench2011_die.x_t and SciBench2011_mand.x_t, into Inspire Extrude to import the die geometry.
- Click the Extrusion ribbon.
-
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 -
Click the exit face of the die assembly to orient the model.
Extract Flow Volume
-
Click the Flow Volume icon to extract flow volume inside
of the die cavity.
-
Click and hold left mouse button while you drag a box around all the die solids
as shown.
-
Release left mouse button to extract flow volume automatically.
Combine Flow Volume
-
Hold CTRL and click on each flow solid as shown.
-
Right-click on either selected solid and click
.
Extract Bearing Region
-
Zoom in to the region where bearing starts.
-
Click the Bearing icon.
-
Select the bearing start surface.
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
-
Click the Organize Volumes based on Length Icon.
-
A micro dialogue will pop up, where you must enter the following
measurements:
- Press OK to close the window.
Create the Billet
-
Click the Create Billet icon.
-
In the small window that pops up, specify the below billet dimensions and press
Enter.
Note: Leave the Skin thickness checkbox unchecked. - Press Esc to exit this panel.
Select the Material
-
Click the Materials icon.
-
Drill down to the respective alloy
-
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. - Click OK to close the Material Database.
-
Click
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
-
Click theSubmit job for analysis icon to run the
simulation.
-
In the Analysis Parameters window that pops up, enter
values as shown.
- Click the Run button.
Status after submitting the job | |
Status after meshing is completed | |
Status when job is running in the solver |
View Simulation Results
-
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. -
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.