3d simulator: extrusion simulation software

MTD SA, Route de Muraz 16, CH 3960 Sierre, Switzerland

[email protected] / www.m-td.com

EXTRUSION SIMULATION SOFTWARE

mailto:[email protected]

MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com

3D Simulator is simulation software developed by extrusion experts for dies makers and extruders.

3DS enables the user to perform fast three-dimensional simulations of the extrusion process enabling one to compute stress and deformation, temperature and fluid flow.

Costly and time-consuming die trials on presses can be replaced by virtual prototyping and testing with computers. Numerical trials allow selecting optimal CAD concepts. This leads to savings on correction costs and longer lifetime of critical parts.

Efficient computer simulations with optimized algorithms enable the user to visualize and understand extrusion material flow, temperature, pressure, mechanical and thermal loads, as well as to design robust die sets by accurately predicting deflections and stresses due to these loads. It enables the user to minimize the die design to prototyping time and reduce the associated costs and overall product development cycle time.

INTRODUCTION



BENEFITS FOR DIES MAKERS

INTEGRATION OF SIMULATION INTO DIE DESIGN PROCESSThe optimized algorithms reduce strictly the calculation time allowing including simulation into “industrial” die design process.The parallel computing option introduced in the new version uses as well the performance of actual multi-core processors, reducing calculation time to few minutes

It enables the designer to control it design, applying modifications and test again the optimized design, or to test different designs in reasonable time.

No prior knowledge of numerical simulation or methods is needed to perform simulations of complex cases. Automatization and user friendly interface enables designers to use immediately the software.



BENEFITS FOR DIES MAKERS

DIES DESIGN OPTIMIZATION

3DS helps designer to:• Define the die shape to optimize the flow balance• Define bearing length• Define the pocket (sink-in)• Predict the quality of seams weld in welding chambers• Predict the profile shape• Minimize the tool deflection, mandrels shift, to meet the product

tolerances.



CAPABILITIES & MAIN FEATURESBASED ON 3D MODEL OF DIFFERENT DIES TYPES

• Solid, semi hollow and hollow dies• Multi-holes dies• Feeders, plates and spreaders

Design your die in 3DOn your CAD softwareor retreive existing 3D model

Create aluminum by subtraction

Create die part by merging dies components, ring and bolster

Export in STEP

Export in STEP



CAPABILITIES & MAIN FEATURESSEVERAL OPTIONS OF SIMULATION PROCESS

• Only with alloy for flow balance, bearings, pocket optimization and quality of seams weld in welding chambers prediction

• With alloy and die for profile shape prediction, die stresses and deformation

• Constant bearing calculation mode to validate quickly a die design and define bearings lengths (coupled with ABC software)

• Real bearing calculation mode to validate bearing defined by designer and quality of seams weld in welding chambers(calculation mode used also for profile with large difference thickness)

• Standard and parallel computing



CAPABILITIES & MAIN FEATURESCALCULATION TYPES

Flow speed of alloy material

Check flow into feeding holes

Check if flow is well balanced between

feeding holes

Visualize flow speed on exit




Pressure of alloy material

Control global pressure to validate press capacity

Check pressure in welding chambers to predict the quality of seams weld




Temperature of alloy material

Control global temperature

Check temperature on exit to identify profile surface quality

problems




Temperature of die

Control global temperature

Check temperature around bearings identify profile surface quality

problems




Die’s stresses

Analyze stresses into die to identify fragile parts and risk of breakages




Displacement : die’s deformations

Check mandrels displacements Check the efficiency of the bolster

Predict tongue deflection

Displacements can be calculated considering mechanical and thermal effectsor only mechanical effect




Displacement : predict profile shape

Control X/Y displacements to define modifications to apply on the profile

Visualize the profile shape deformation

deformation



PROCEDUREOVERVIEW

Simulation process is realized in few stepsProcess is partially automatized to let the designer control the processAutomatization can be done on demand

PROCESS CHARTCAD preparation Simulation type

selection

Define modifications and restart the process if necessary

Simulation calculation

Data processing analysisSimulation data preparation



PROCEDURE / PROCESS CHARTSTEP 1 : CAD PREPARATION

Design your die project in 3DCreate alloy and/or die stackExport them as STEP filesUse only alloy to control flow balance problems or to optimize process parametersUse alloy and die for a complete analysis

CAD model

Alloy part defined by subtractionIncluding billet length

Die step model is defined including :• Dies parts• Ring • Bolster

Necessary to consider real conditions for temperature, stresses and deformation analysis

STEP model for simulation



PROCEDURE / PROCESS CHARTSTEP 2 : simulation type selection

Define the simulation type:• Nb of processing units 1 or more for standard or parallel

computing

• Simulation type :Calculation type1 for dies designer: to make a fast simulation (recommended for first analysis or flow balance optimization)3 for dies designer: to validate bearing defined by designer or if profile has large thickness difference, for extruders: to analyze die or production defect on existing die

Model used1 (alloy only) for first analysis or if you are confident in die deformations0 (alloy + die) for final analysis or if you need to control die stresses and deformation



PROCEDURE / PROCESS CHARTSTEP 2 : simulation data preparation

Define geometrical data:• Enter alloy type• Import 3D models• Enter geometrical data

Define mesh models:• For simple calculation prepare only alloy mesh model• For complete calculation prepare alloy and die mesh model

Mesh generation is made automatically



PROCEDURE / PROCESS CHARTSTEP 3 : simulation calculation

Start calculations• Flow to check flow balance and pressure

• Alloy + die + Temperature to check temperature into alloy and prepare thermo-mechanical of die(if you make only alloy simulation, only temperature alloy will be calculated)

• Structure + temperature to calculate dies stresses • Displacement to check dies displacements

Prepare data for analysis• As described into solvers windows, it’s necessary to post-

process data after each step to generate data for the next simulation

• Prepare data for each step as defined into the windows



PROCEDURE / PROCESS CHARTSTEP 4 : simulation results analysis

First, analyze alloy results• Check flow balance, bearings speed in first• Control pressure

→ Dies designer: define modifications to apply on die project and run another calculation if necessary

• Check alloy temperature (optional)

Second, analyze die results• Check die stress• Analyze die deflection to apply modification on profile shape



PROCEDURE / BEST PRACTICEPROCESS CHART FOR A BEST PROJECT

Work on alloySimulate and

analyze AL flow(and pressure)

Apply modification on

die project

Go back to the start

Prepare die model

Flow balance ok

Simulate and analyze temperature

Die stress and displacement

Apply modification on die project



PROCEDURE / BEST PRACTICEPROCESS CHART FOR QUALITY IMPROVEMENT

Prepare alloy and die models

Simulate and analyze AL flow(and pressure)

Simulate and analyze

temperature

Simulate and analyze die stress and deflection

Define modifications and apply them on

3D model

Make a new process to validate modifications

Control flow balance and

bearing length

Control quality surface

Control cause of breakages

Profile shape tolerancesImbalance flow due to die

deformation

Ok

Realize modifications on physical

die

Test on press



PROCEDURE / BEST PRACTICEPROCESS CHART FOR EXTRUSION PROCESS OPTIMIZATION

Work on alloyDefine

parameter set

Simulate and analyze AL flow

and pressure

Simulate and analyze

temperature

modify parameter set

Control profile speedControl pressure

Control profile temperature

Ok

Apply parameter

set on press



OTHER MTD’S SERVICES

3D CAD DESIGNIf you don’t design in 3D dies, we can do it for you from 2D drawings.

SIMULATIONWe offer also the possibility to realize the complete analysis in a short time from your 2D drawings and the necessary data.We offer different level of services:• Simple calculation• Simulation and analysis of design• Simulation and modifications (delivery of 3D model ready to

manufacture)


3d simulator: extrusion simulation software

Technology