Knowing how your design will react as it withstands use is important. However, if you are able to discover a negative reaction or behavior before you go to production you can make the needed adjustments and save your company lots of time and money. When dealing with metal designs, Altair Inspire Extrude Metal is the simulation tool you need.
Altair Inspire Extrude Metal
Altair Inspire Extrude Metal, formerly Click2Extude Metal, is a simulation-driven design environment software offering complete casting simulation in five easy steps within a highly intuitive user experience. Created with its end users in mind, it allows them to enhance and optimize the extrusion process to drastically improve productivity and quality.
The software simulation environment has been upgraded to address a wide variety of users from beginners to experts and from production engineers to process designers.
To use Altair Inspire Extrude Metal, start with importing die geometry, which can be found in any popular 3D CAD package or in a neutral format. Once it's loaded, orient the die assembly so the extruding part is coming out in the positive C direction by selecting the curved arrow in the orient model icon. After that, click on the flow volume icon, draw a window around the entire die assembly and release the mouse for automatic extraction of the flow volume. If you need to, pin holds can be deleted by selecting the delete button on the user keyboard. To combine the two parts off the two portholes into one flow volume just click the combine icon.
You can define the bearing length with dimensions by clicking on the bearing icon and by selecting the starting surface. Altair Inspire Extrude Metal will create solids for bearing and profile but you can modify them as needed. In the advanced version, you can also optimize the bearing length. You want to combine the remaining areas and click on the organize icon. Next, you'll want to organize the flow volume by entering the portholes length, weld chamber length and pocket length. Altair Inspire Extrude Metal will automatically build the solids to a buffling and organize them to the respective components. This is necessary to better visualize and interpret the results, as well as improve the ability to create a quality mesh.
Create Billet and Material Selection
After you have the full volume organized, click on the billet icon and specify the billet dimensions. Leave the box for skin thickness unchecked. Altair Inspire Extrude Metal will automatically adjust the billet size to the specified dimensions and then press Esc to exit the panel. Click on the materials icon to choose the alloy or you can use the search icon. You can then save it by right-clicking un-default materials as well.
Perform Extrusion Simulation
Once the model setup is completed, save the model to a folder that contains no previous results within it. Next, click on the analysis icon to set process parameters, such as:
- Ram speed
- Preheat temperature
- Container temperature
- And more
It's now finally time to run the simulation by clicking on the run icon. The status bar allows you to know what task Altair Inspire Extrude Metal is performing and will display a green check mark when the simulation is complete.
After the simulation is finished, you can move onto post-processing the outcome. Click on the analysis icon to load the results. Adjust the model to the desired orientation and then click on the deform icon to see the deformation of the profile nose. This can be animated by clicking on the play button and the speed can be controlled by the speed scrollbar. Next, select pressure under result types. The contour represents the resulting extrusion loads on the die surfaces, which is used to compute tool deflection. After that, select temperature. This shows the temperature change during extrusion due to friction and deformation. The weld surface contour shows the contour of the weld surface forms by different streams of material flow in the weld chamber die, the weld strength and the weld regions. If the value is equal to one, it's considered a very poor, weak weld and if the value is equal to five, it'a considered a good, strong weld. To discover how the recrystallization occurs during the extrusion click on grain sized contour and section cuts will generate the results for any contour during any section. The entire extrusion process can be easily modeled, solved and analyzed through Altair Inspire Extrude Metal and it's comprehensive and user-friendly interface.
Want to see all of this in action? Check out our video playlist to get a walk-through of all the steps above.