Experimentally Validated Finite Element Simulation of Aluminum Extrusion of a Micro-Multiport Condenser

Abstract

The research aims at developing and experimentally validating a finite element (FE) model that can be used to optimize the geometry of a porthole die for aluminum extrusion to maximize tooling life while achieving the required product quality. A commercial FEA code that was validated in another study, namely DEFORM 3D®, is used to create a thermo-mechanical model that closely represents the highly non-linear large deformation nature in the extrusion process. Both Lagrangian formulation and Eulerian formulation are explored. Using the Updated Lagrange FE analysis, the tooling components of the modular die are assumed to be rigid in order to achieve the right friction coefficients to validate the experimental data collected during trail runs of the modular die. A steady state FE analysis is run to predict the maximum weld pressure between the mandrel port webs. The simulation is used to study the effects of port opening, port lead angle, and angle intercept distance, on effective stress, material velocity, and welding pressure. Different parameters are predicted, including temperature distribution, wear, stress and stress concentration, extrusion load, exit velocity, exit temperature, material flow through the die port, etc. The insight gained from these simulations can be used to optimize the geometry of the die mandrel.