Altair Case Studies Improving Extrusion Die Life and Efficiency with Altair HyperXtrude

	Improving Extrusion Die Life and Efficiency with Altair HyperXtrude Altair

Improving Extrusion Die Life and Efficiency with Altair HyperXtrude

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation Networks & Connectivity - Routers & Bridges
Applicable Industries	Aerospace Automotive
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Manufacturing Process Simulation Virtual Reality
Services	Testing & Certification
Challenge	The aluminum extrusion industry has been facing significant challenges due to the shorter life and frequent failures of dies used in the extrusion of hard alloys. These issues have a direct impact on productivity and increase production costs. The situation is further complicated by the increasing use of aluminum extrusions in various industries such as automotive, aerospace, railway, medical, architectural, and others. These applications have stringent strength and surface quality requirements, often necessitating the use of newer and harder alloys. Traditional die design practices have proven inadequate for these new demands, resulting in dies with shorter lifespans. The Conglin Group, a leader in Chinese aluminum fabrication technology, sought to address these challenges and meet the growing demands from both domestic and international markets. Read More
About Customer	The Conglin Group is a leading player in the Chinese aluminum fabrication industry. In recent years, they have seen a significant increase in the use of aluminum extrusions in a wide range of applications, including automotive, aerospace, railway, medical, architectural, and other industries. These applications have stringent strength and surface quality requirements, often requiring the use of newer and harder alloys. The Conglin Group has been at the forefront of addressing these challenges and meeting the ever-increasing demands from both domestic and international markets. They have combined their design philosophy, manufacturing experience, and skills in using finite element simulation software to overcome the challenges posed by extruding hard and newer alloys. Read More
Solution	The Conglin Group turned to Altair HyperXtrude, a finite element simulation software, to predict die performance and conduct virtual die tryouts. By analyzing the extrusion dies using HyperXtrude and interpreting the simulation data, Conglin was able to accurately predict the service life of an extrusion die. The software allowed them to identify areas of stress concentration and their intensity, which are critical factors in determining the life and productivity of a die. Based on the insights gained from the software, Conglin was able to modify and test die designs to improve their lifespan and reduce the number of die trials. For instance, in one case, they redesigned a die that initially fractured after extruding just 10 billets to one that did not fail even after extruding 100 billets. This was achieved by adjusting the design to overcome high levels of stress and introducing several portholes to feed material to different regions of the die, producing a balanced flow at the die exit. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Networks & Connectivity - Routers & Bridges

Applicable Industries

Aerospace

Automotive

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Manufacturing Process Simulation

Virtual Reality

Services

Testing & Certification

Challenge

The aluminum extrusion industry has been facing significant challenges due to the shorter life and frequent failures of dies used in the extrusion of hard alloys. These issues have a direct impact on productivity and increase production costs. The situation is further complicated by the increasing use of aluminum extrusions in various industries such as automotive, aerospace, railway, medical, architectural, and others. These applications have stringent strength and surface quality requirements, often necessitating the use of newer and harder alloys. Traditional die design practices have proven inadequate for these new demands, resulting in dies with shorter lifespans. The Conglin Group, a leader in Chinese aluminum fabrication technology, sought to address these challenges and meet the growing demands from both domestic and international markets.

About Customer

The Conglin Group is a leading player in the Chinese aluminum fabrication industry. In recent years, they have seen a significant increase in the use of aluminum extrusions in a wide range of applications, including automotive, aerospace, railway, medical, architectural, and other industries. These applications have stringent strength and surface quality requirements, often requiring the use of newer and harder alloys. The Conglin Group has been at the forefront of addressing these challenges and meeting the ever-increasing demands from both domestic and international markets. They have combined their design philosophy, manufacturing experience, and skills in using finite element simulation software to overcome the challenges posed by extruding hard and newer alloys.

Solution

The Conglin Group turned to Altair HyperXtrude, a finite element simulation software, to predict die performance and conduct virtual die tryouts. By analyzing the extrusion dies using HyperXtrude and interpreting the simulation data, Conglin was able to accurately predict the service life of an extrusion die. The software allowed them to identify areas of stress concentration and their intensity, which are critical factors in determining the life and productivity of a die. Based on the insights gained from the software, Conglin was able to modify and test die designs to improve their lifespan and reduce the number of die trials. For instance, in one case, they redesigned a die that initially fractured after extruding just 10 billets to one that did not fail even after extruding 100 billets. This was achieved by adjusting the design to overcome high levels of stress and introducing several portholes to feed material to different regions of the die, producing a balanced flow at the die exit.

Impact #1	The use of Altair HyperXtrude has provided the Conglin Group with valuable insights into the material flow and balancing of the die. It has also been instrumental in tool deflection analysis, helping the group understand die performance and improve design to increase extrusion service life. By studying the die performance using HyperXtrude at the design stage, Conglin has been able to arrive at designs that have the longest life, thereby greatly reducing the cost of aluminum extrusions of hard alloys. This has not only improved their operational efficiency but also enhanced their ability to meet the stringent requirements of various industries. The success of this approach demonstrates the value of using advanced simulation tools in understanding and overcoming design challenges in the aluminum extrusion industry.

Impact #1

The use of Altair HyperXtrude has provided the Conglin Group with valuable insights into the material flow and balancing of the die. It has also been instrumental in tool deflection analysis, helping the group understand die performance and improve design to increase extrusion service life. By studying the die performance using HyperXtrude at the design stage, Conglin has been able to arrive at designs that have the longest life, thereby greatly reducing the cost of aluminum extrusions of hard alloys. This has not only improved their operational efficiency but also enhanced their ability to meet the stringent requirements of various industries. The success of this approach demonstrates the value of using advanced simulation tools in understanding and overcoming design challenges in the aluminum extrusion industry.

Benefit #1	Extended the service life of the mold, with one redesigned die not failing even after extruding 100 billets compared to the original design that fractured after just 10 billets.
Benefit #2	Reduced the cost of production by improving die life and reducing the number of die trials.
Benefit #3	Improved productivity by increasing the number of billets that can be extruded before die failure.

Benefit #1

Extended the service life of the mold, with one redesigned die not failing even after extruding 100 billets compared to the original design that fractured after just 10 billets.

Benefit #2

Reduced the cost of production by improving die life and reducing the number of die trials.

Benefit #3

Improved productivity by increasing the number of billets that can be extruded before die failure.

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Overview

Improving Extrusion Die Life and Efficiency with Altair HyperXtrude

Operational Impact

Quantitative Benefit