Experimental results, which indicate a significant influence of the reinforcing elements on the material flow during composite extrusion with high reinforcing volumes, are presented. In order to analyze the process numerically, finite element simulations with models taking into account the reinforcing elements were carried out. The results are discussed with regard to the material flow and the load of the reinforcing elements.
Extrusion processes can be utilized for production of parts characterized by complex shapes; furthermore, nowadays, the market needs are always more driving towards the manufacture of components with thinner thickness for weight and volume reduction. As a consequence, the process complexities are growing up but, nevertheless, quality and productivity have to be guaranteed by companies if they want to survive in an increasingly competitive society.In this work, a ductile criterion was utilized to highlight which variations due to thickness reduction can bring to superficial defects in extruded components. The study was carried out by using a suitable die geometry where thickness changes can be performed keeping constant the other geometrical variables. The die optimization was carried out by numerical simulations which were utilized for homogenizing the extruded velocity at the exit of the bearing zone. Different working conditions were numerically analyzed and geometrical die changes were performed to highlight their influences on the superficial integrity of the extruded parts.
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