No abstract

In the simulation of bulk forming processes the validation of the applied simulation models is necessary. Then, predictive simulations are possible. A visualisation method is an advanced way to create additional evaluation parameters. In this work, the upscaling of a newly developed non-destructive method from semi-industrial to near-industrial scale for metal extrusion of aluminium alloys is presented. A copper coating, which deforms with the billet material, was applied to one half (in the longitudinal direction) of a cast billet and detected by computed tomography (CT). The copper pattern was applied by a plasma coating technology to determine the deformation of the billet material during the process until the final profile. A detailed analysis of the upscaled method with improved geometric setup shows the superiority of the newly chosen properties enabling a complete determination of strain state also in the profile.