Computer modeling of the continuous forming extrusion process of AA6061 alloy

This paper presents a detailed application of the finite-element computer modeling technique for the analysis of the continuous forming (Conform(TM), a trademark owned by BWE International, Ashford, Kent, UK) extrusion process. The model is used to predict the contact behavior between the Conform(TM) wheel-groove and the workpiece. The modeling results predict stress, strain, strain rate and temperature fields that are in good agreement with experimental data obtained through on-line control data acquisition techniques. The model has been validated with temperature data obtained by thermocouple measurements of die-face temperatures. The excellent agreement between the calculated and the measured temperatures indicates that, for the first time, a good prediction capability has been developed for the complex mechanisms occurring in this forming process. (C) 1998 Elsevier Science S.A. All rights reserved.