Finite element analysis and die design for extrusion of complex-shaped parts

The objective of this study is to propose a guideline for designing the shapes and dimensions of the flow-guide of the die for extrusion of complex-shaped parts. A commercial finite element package "DEFORM 3D" is employed to simulate the plastic deformation behavior of the billet inside the die during extrusion of complex-shaped parts. The effects of position and dimension of the flow-guide on the extrusion load as well as the curvature at the exit of the die are discussed. From the comparisons, it is known that appropriate designs of the flow-guide can greatly decrease the curvature of the extruded product.