Aluminium Extrusion Simulation - Two success cases with our partner Pandolfo Alluminio

‘I'm Mr Wolf, I solve Problems’ could be the correct phrase to start this post....

And that is exactly what we do at Phoenix: we solve problems and find solutions in close contact with our customers.

Below we tell you how, through technological innovations, we were able to design a die that was good at the first test. #ZEROTRIALDIE

Together and thanks to our long-standing partner Pandolfo Alluminio , we co-developed a design for two complicated dies through advanced Q-Form simulations.

1) Project nr. FGPE3256_10

Received from our partner, Pandolfo Allumio SpA, a feasibility request regarding the above profile. Considering the level of complexity and the necessity to have the best result at the first test, was decided to simulate the extrusion process after the project.

The first standard simulation

The result of the 1° Standard simulation was under expectations and request an optimization.

The standard & optimized advanced simulation

In Fig. 1, you can see the result of the second Standard simulation re-run after the project’s optimization process thanks to the data collected with the first simulation. With this representation is possible to appreciate the improvements in terms of balance respect the first one.

While in Fig. 2 we find the results of the Advanced simulation (simulation that allows you to have a complete picture of the flows during the entire billet extrusion process) which are those used to allow the project’s improvements.

The results - Good at first test

At first extrusion we obtained the perfect profile !!! GOOD AT FIRST TEST!!! #ZEROTRIALDIE!!!

2) Project nr. NZH204_10

The first standard simulation

The information received from the first simulation allowed us to realise that die design could be improved and optimised, defining also where to take action.

The standard & optimized advanced simulation

In Fig. 1, you can see the result of the second Standard simulation re-run after the project’s optimization process thanks to the data collected with the first simulation. With this representation is possible to appreciate the improvements in terms of balance respect the first one.

While in Fig. 2 we find the results of the Advanced simulation (simulation that allows you to have a complete picture of the flows during the entire billet extrusion process) which are those used to allow the project’s improvements.

The results - Good at first test

And also in this case... #ZEROTRIALDIE!!!

Extrusion simulation benefits

The benefits of this technology are several including:

• Reducing the number of trials

Simulation is the key tool for optimised design aimed at producing a high-performance product from the very first trials.

• Preventing failures and/or very short die life

Analytical and/or empirical formulae for strength testing are quite reliable. But simulation allows you to identify, with absolute precision, all structural criticalities, enabling us to optimise them already at the design stage.

• Increased productivity

Pressures and temperatures are crucial factors that directly affect the productivity of the extrusion process. Factors that can be analysed in the simulation phase to achieve optimal productivity.

• Predicting defects on the extrudate

Through simulation, defects such as lack of profile fill and streaks appearing on the outer surface of the profile can be predicted.