HyperXtrude process modeling of Laboratory-scale experiments
HyperXtrude is a commercial extrusion-dedicated simulation software developed by Altair Inc. to investigate die design and material flow in the extrusion process of metals and polymers. The purpose of this tool is to enable die designers and production engineers to accurately model the thermo-mechanical behavior of the billet material and thus validate die designs in early stages with the intention of reducing and/or eliminating costly die trials. Die trial is a prevalent practice in the industry which is marked by expensive time-consuming die iterations aimed at producing balanced material flow with minimum profile distortion.
HyperXtrude is a finite-element based code designed to model/simulate the non-isothermal material flow during metal extrusion. The code uses an Eulerian formulation of the fundamental differential equations that govern flow and heat transfer of non-Newtonian incompressible viscous fluids. As such, the code uses a fixed-space control volume representation of the problem domain through which the material flows as it is extruded through the tooling. Hence, the code does not capture the transient aspects (load and temperature) of the process as the material fills the die (pocket and bearing area). In this respect, HyperXtrude users need to set-up their simulation model to include the extended flow domain to represent the bearing area and profile. The problem setup procedure in HyperXtrude is illustrated below.
| Solution setup methodology in HyperXtrude
Post Process - Streamline conversion and Texture/Twinning Predictions