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Creep fatigue in extrusion dies - modelling and simulation
By Christof Sommitsch, Thomas Wlanis, Thomas Hatzenbichler, and Volker Wieser
Damage, simulation, aluminium alloy, modelling, extrusion
During hot extrusion of aluminium alloys, extrusion tools experience cyclic temperature changes as well as multiaxial loading. To improve the service life of the tools, cleaner materials with advanced hot strength are designed and optimised process control is performed. For the improvement of process guiding and a comparison of lifetime behaviour of different hot work tool steels, modelling and simulation are appropriate means. The extrusion process for both a circular solid shape and a complex section was simulated with a finite element programme to find the stress and temperature history within the dies and additionally, for the complex section, to define the boundary conditions for a subsequent cyclic simulation of the die loads during service. Inelastic constitutive equations were implemented into a FEM code to describe the strain hardening and time recovery ef-fects. They include a thermo-mechanical isotropic hardening and two non-linear kinematic hardening laws. A damage-rate model predicts failure and thus the lifetime of the extrusion die.
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