In this work, different friction models available in HyperXtrude had been investigated in the context of hot forward extrusion simulation of aluminum alloys. Extrusion trials were carried out for EN AW 6060 and EN AW 6082 at different temperatures and ram speeds. The extrusion forces as well as material temperatures near the exit of the die were recorded and used for the validation of the simulations. FE-simulations of each extrusion trial were carried out in HyperXtrude. Initially, friction models were calibrated for only two extrusion trials. Then, these calibrated friction models were used to simulate the extrusion trials with different process parameters. Reasonably good agreements were observed between experiments and simulations in terms of extrusion forces. However, the simulations overpredicted the material temperature by almost up to 40 °C for extrusion trials with high ram speed.

Coarse grains at or near the surfaces of extruded aluminum profiles can have a major detri-mental influence on their ductility and surface quality. Thus, the extrusion industry aims to minimizecoarse grains while increasing the productivity of the process. Peripheral Coarse Grains (PCG) de-velop depending on local state variables such as temperature, strain and strain rate. Here we presenta microstructure based material model implemented into HyperXtrude™, capable of predicting thedevelopment of PCG by combining geometric Dynamic Recrystallization (gDRX) and conventionalgraingrowthmodels.Duetoitshistorydependence,themodelisimplementedtorunduringthewholetransient extrusion simulation. The first results of the predicted ram force as well as final grain distri-bution in the profile show reasonable agreement with experimental trials and electron backscattereddiffraction results.