Possibility to predict extrusion die incidental fracture by finite element simulation

Finite element (FE) simulation of the extrusion process can minimize the time and effort in die design and assist with the optimization of technological parameters for obtaining high quality profiles. However, there are cases when extrusion die fails unexpectedly despite the simulations predicting a positive outcome. In this paper the incidental failure of the die used by Capral Ltd for extrusion of the T-shape profile from AA6082 aluminium alloy is analysed. FE simulation complemented with a damage modelling is shown to be valuable tool for establishing the reasons for the die failure and for developing the strategy to prevent such an event.