A three-dimensional finite element simulation of the warm extrusion of AZ31 alloy billets

Extrusion of magnesium billets is associated with large deformations, high strain rates and high temperatures, which results in computationally challenging problems in process simulation. A series of experiments were done to obtain the simulation parameters: stressstrain curves, friction factors and heat transfer coefficient etc. Three-dimensional, thermo-mechanically coupled finite element simulations of extruding a wrought magnesium alloy AZ31 into a small bar at certain ram speeds were performed. The computed model was rotational symmetric and built up by meshing. Computed parameters including workpiece material characteristics and process conditions (billet temperature, reduction ratio, and ram speed) were taken into consideration. The distributions of temperature were different comparing the transient-state extrusion with steady-state extrusion. The extrusion simulation was the reliable predictions of strain rate, effective strains, effective stresses and metal flow velocity in an AZ31 billet during direct extrusion. © 2010 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.