Measuring the Deformation of a Flat Die by Applying a Laser Beam on a Reflecting Surface

Abstract

The design of extrusion dies depends on the experience of the designer. After the die has been manufactured, it is tested during an extrusion process and machined several times until it works properly. The die is designed by a trial and error method which is expensive interms of time consumption and the amount of scrap. Research is going on to replace the trial pressing with finite element simulations that concentrate on material and tool analysis. In order to validate the tool simulations, an experiment is required for measuring the deformation of the die. Measuring the deformation of the die is faced with two main obstacles: high temperature and little free space. To overcome these obstacles a method is tried, which works by applying a laser beam on a reflecting surface. This cheap method is simple, robust and gives good results. This paper describes measuring the deformation of a flat die used to extrude a single U shape profile. In addition, finite element calculation of the die is performed. Finally, a comparison is performed between experimental and numerical results.

Towards the flexible and near-net-shape production of three-dimensionally curved extrusion profiles

“…11) [12]. In comparison to this awareness the orifice of the round tube cross section used in the presented experiments is also changed during the extrusion process, and so the extrusion ratio differs from the target value which is calculated by the target cross section of the tube with a diameter of 40 mm and a wall thickness of 2 mm.…”

Coupled analysis of material flow and die deflection in direct aluminum extrusion

“…The computational time for the two procedures is checked. The angular deflection of the tongue for the die employed in extruding the profile is measured experimentally in an industrial environment [4].…”

“…Currently, the material flow and the tool deformation in an aluminum extrusion process are mostly calculated by a decoupled method [1,4,3]. In the decoupled method, the material flow of the aluminum is computed by a Eulerian formulation under the assumption of a rigid die.…”

Aluminium extrusion with a deformable die

“…It consists of four main chapters. Chapters two, three, four and five are based on papers which have been published elsewhere [51][52][53]. Finally, the extrusion benchmarks organized on the occasion of the extrusion conferences of 2007 and 2009 [21,31] are analyzed in chapter six.…”