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Optimization of die design for extrusion of 6xxx series aluminum alloys through finite element analysis: a critical review

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Abstract

This paper presents an overview of the recent advances in optimization of die design through finite element analysis for aluminum alloys of 6xxx series. The die design and optimization play a crucial role in the production of 6xxx series alloys, in order to attain high quality’s final products. Before the use of finite element analysis (FEA) in aluminum extrusion industry, many experiments and modifications are needed until an acceptable product becomes available. The use of finite element analysis acquires a key role in the direction of eliminating trials and defective extrudates and use is gaining more and more ground through most of the manufacturers. This review will show how various studies try to enhance the performance of the extrusion dies through simulations and how the majority of the most common defects could be prevented if the use of the suitable software and techniques are implemented. The main covered areas from the current review are material flow optimization, flow balance in extrusion of complex aluminum profiles, spread extrusion die design, optimization of porthole extrusion dies, front end and back end defects, die bearing geometry and surface defects, automatic die design optimization and liquid nitrogen die cooling.

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  1. School of Science and Technology, Digital Manufacturing and Materials Characterization Laboratory, International Hellenic University, 14th km Thessaloniki-Moudania, 57001, Thermi, Greece

    Evangelos Giarmas & Dimitrios Tzetzis

  2. Production Division, Alumil SA, 61100, Kilkis, Greece

    Evangelos Giarmas

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  1. Evangelos Giarmas
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Giarmas, E., Tzetzis, D. Optimization of die design for extrusion of 6xxx series aluminum alloys through finite element analysis: a critical review. Int J Adv Manuf Technol 119, 5529–5551 (2022). https://doi.org/10.1007/s00170-022-08694-3

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