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<p>Using the finite volume method (FVM) to simulate aluminum alloy extrusion processes has proven to be a feasible strategy since it can avoid serious mesh distortion and frequent re-meshing. In this paper, based on the finite volume mathematical models for nonsteady state aluminum alloy extrusion processes, a finite volume program was developed and integrated into OpenFOAM. A moving grid system was adopted to deal with the variation of the calculation domain caused by the movement of the extrusion ram. The coupled level set and volume-of-fluid (CLSVOF) method was employed to accurately capture the free surface of the material. Automatic time increment adjustment was introduced to improve the stability and efficiency of the simulation. Two extrusion cases of T-shaped and hollow aluminum alloy profiles were analyzed with the developed program. The simulated results of flow patterns, fields of velocity, and temperature are in good agreement with those of DEFORM-3D. The surface quality obtained by OpenFOAM is superior to that obtained by DEFORM-3D, highlighting the efficacy of the FVM approach in extrusion simulation.</p>

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Finite volume simulation of nonsteady state aluminum alloy extrusion process using OpenFOAM

  • 期刊论文

  • 发表日期：

    2025年8月19日

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  • Guofang Zhang,
  • Cunsheng Zhang,
  • Jiabo Zhao,
  • Limin Zhang,
  • Zijie Meng,
  • Haijian Xu

摘要

Using the finite volume method (FVM) to simulate aluminum alloy extrusion processes has proven to be a feasible strategy since it can avoid serious mesh distortion and frequent re-meshing. In this paper, based on the finite volume mathematical models for nonsteady state aluminum alloy extrusion processes, a finite volume program was developed and integrated into OpenFOAM. A moving grid system was adopted to deal with the variation of the calculation domain caused by the movement of the extrusion ram. The coupled level set and volume-of-fluid (CLSVOF) method was employed to accurately capture the free surface of the material. Automatic time increment adjustment was introduced to improve the stability and efficiency of the simulation. Two extrusion cases of T-shaped and hollow aluminum alloy profiles were analyzed with the developed program. The simulated results of flow patterns, fields of velocity, and temperature are in good agreement with those of DEFORM-3D. The surface quality obtained by OpenFOAM is superior to that obtained by DEFORM-3D, highlighting the efficacy of the FVM approach in extrusion simulation.