3D Simulator: Extrusion simulation software

MTD SA,
Route de Muraz 16, CH 3960 Sierre, Switzerland
info@m-td.com / www.m-td.com
EXTRUSION SIMULATION
SOFTWARE

MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland info@m-td.com / 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 PROCESS
The 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 FEATURES
BASED ON 3D MODEL OF DIFFERENT DIES TYPES
• Solid, semi hollow and hollow dies
• Multi-holes dies
• Feeders, plates and spreaders
Design your die in 3D
On your CAD software
or retreive existing 3D
model
Create aluminum by subtraction
Create die part by merging dies components,
ring and bolster
Export in STEP
Export in STEP

SEVERAL 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

CALCULATION 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

CALCULATION TYPES
Pressure of alloy material
Control global pressure to
validate press capacity
Check pressure in welding chambers
to predict the quality of seams weld

CALCULATION TYPES
Temperature of alloy material
Control global
temperature
Check temperature on exit to
identify profile surface quality
problems

CALCULATION TYPES
Temperature of die
Control global
temperature
Check temperature around bearings
identify profile surface quality
problems

CALCULATION TYPES
Die’s stresses
Analyze stresses into die to identify fragile parts and risk of breakages

CALCULATION TYPES
Displacement : die’s deformations
Check mandrels
displacements
Check the efficiency of the bolster
Predict tongue deflection
Displacements can be calculated considering mechanical and thermal effects
or only mechanical effect

CALCULATION TYPES
Displacement : predict profile shape
Control X/Y displacements to define
modifications to apply on the profile
Visualize the profile shape
deformation
deformation

PROCEDURE
OVERVIEW
Simulation process is realized in few steps
Process is partially automatized to let the designer control the process
Automatization can be done on demand
PROCESS CHART
CAD preparation
Simulation type
selection
Define modifications and restart the process if necessary
Simulation
calculation
Data processing analysis
Simulation data
preparation

PROCEDURE / PROCESS CHART
STEP 1 : CAD PREPARATION
Design your die project in 3D
Create alloy and/or die stack
Export them as STEP files
Use only alloy to control flow balance problems or to optimize process
parameters
Use alloy and die for a complete analysis
CAD model
Alloy part defined by subtraction
Including 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

STEP 2 : simulation type selection
Define the simulation type:
• Nb of processing units 1 or more for standard or parallel
computing
• Simulation type :
Calculation type
1 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 used
1 (alloy only) for first analysis or if you are confident in die
deformations
0 (alloy + die) for final analysis or if you need to control die
stresses and deformation

STEP 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

STEP 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

STEP 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 PRACTICE
PROCESS CHART FOR A BEST PROJECT
Work on alloy
Simulate 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

PROCESS 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 tolerances
Imbalance flow due to die
deformation
Ok
Realize
modifications
on physical
die
Test on press

PROCESS CHART FOR EXTRUSION PROCESS OPTIMIZATION
Work on alloy
Define
parameter set
Simulate and
analyze AL flow
and pressure
Simulate and
analyze
temperature
modify parameter set
Control profile speed
Control pressure
Control profile
temperature
Ok
Apply
parameter
set on press

OTHER MTD’S SERVICES
3D CAD DESIGN
If you don’t design in 3D dies, we can do it for you from 2D drawings.
SIMULATION
We 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

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