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<p>The material flow during the extrusion process plays a crucial role in controlling the quality of profiles. In this paper, the extrusion of aluminum profiles was simulated using the finite volume based software OpenFOAM. Mathematical models involving governing equations, constitutive equations, and the initial and boundary conditions were established for the three-dimensional steady-state extrusion process, and the corresponding program codes were developed based on the simpleFoam solver in OpenFOAM. Three typical extrusion processes of aluminum alloy profiles with h-shape, irregular shape, and hollow pipe shape were analyzed with the developed codes. The simulated results of flow velocity, temperature, and strain-rate are generally in agreement with those predicted by HyperXtrude, demonstrating the feasibility and reliability of the proposed numerical models and methods.</p>

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Numerical simulation of the steady-state aluminum alloy extrusion process with finite volume method

  • 期刊论文

  • 发表日期：

    2025年9月6日

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

摘要

The material flow during the extrusion process plays a crucial role in controlling the quality of profiles. In this paper, the extrusion of aluminum profiles was simulated using the finite volume based software OpenFOAM. Mathematical models involving governing equations, constitutive equations, and the initial and boundary conditions were established for the three-dimensional steady-state extrusion process, and the corresponding program codes were developed based on the simpleFoam solver in OpenFOAM. Three typical extrusion processes of aluminum alloy profiles with h-shape, irregular shape, and hollow pipe shape were analyzed with the developed codes. The simulated results of flow velocity, temperature, and strain-rate are generally in agreement with those predicted by HyperXtrude, demonstrating the feasibility and reliability of the proposed numerical models and methods.