TY - JOUR

T1 - Approaches for the Simulation of Composite Extrusion - Possibilities and Limits

AU - Schwane, Martin

AU - Kloppenborg, Thomas

AU - Haase, Matthias

AU - Ben Khalifa, Noomane

AU - Tekkaya, A. Erman

PY - 2015

Y1 - 2015

N2 - During continuous composite extrusion, endless elements, such as steel wires, are embedded in the aluminum base material. Due to the complex material flow conditions, the design of composite extrusion dies is challenging. Therefore, numerical simulations are applied in order to determine appropriate die geometries and process parameters. In this paper, an overview of different modeling approaches for the simulation of continuous composite extrusion, which have been developed at the Institute of Forming Technology and Lightweight Construction (IUL) in recent years, is presented. In particular, fundamental differences of the methods are related to the utilized finite element approaches, i.e. the Eulerian formulation and the Lagrangian formulation. Furthermore, it is discussed whether it is necessary to consider the embedded elements physically in the simulation model. The advantages, drawbacks, and limits of the different approaches are presented, in particular with regard to material flow, reinforcing element position in the profile, and load on reinforcing elements. Furthermore, the simulation results are compared with experiments.

AB - During continuous composite extrusion, endless elements, such as steel wires, are embedded in the aluminum base material. Due to the complex material flow conditions, the design of composite extrusion dies is challenging. Therefore, numerical simulations are applied in order to determine appropriate die geometries and process parameters. In this paper, an overview of different modeling approaches for the simulation of continuous composite extrusion, which have been developed at the Institute of Forming Technology and Lightweight Construction (IUL) in recent years, is presented. In particular, fundamental differences of the methods are related to the utilized finite element approaches, i.e. the Eulerian formulation and the Lagrangian formulation. Furthermore, it is discussed whether it is necessary to consider the embedded elements physically in the simulation model. The advantages, drawbacks, and limits of the different approaches are presented, in particular with regard to material flow, reinforcing element position in the profile, and load on reinforcing elements. Furthermore, the simulation results are compared with experiments.

KW - Composite extrusion

KW - FEM

KW - Material flow

KW - Modeling

KW - Process analysis

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=84963614937&partnerID=8YFLogxK

U2 - 10.1016/j.matpr.2015.10.011

DO - 10.1016/j.matpr.2015.10.011

M3 - Journal articles

AN - SCOPUS:84963614937

VL - 2

SP - 4771

EP - 4777

JO - Materials Today: Proceedings

JF - Materials Today: Proceedings

SN - 2214-7853

IS - 10 (Part A)

ER -