Ensuring Extrusion Product Quality at Die Design Stage
Transcript of Ensuring Extrusion Product Quality at Die Design Stage
Innovation Intelligence®
Ensuring Extrusion Product
Quality at Die Design Stage.
Jeff Skinner
Thumb Tool & Engineering
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Outline
• TTE – Overview
• Design problems
• Analysis and correction of die #3902
• Analysis and correction of die #Cobr
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
About TTE – Gemini Group
• Thumb Tool & Engineering was founded in 1972.
• Along with Mid-south/Central Extrusion Dies we are the 2nd largest builder of extrusion dies in
the world. We are also the best.
• We belong to the Gemini Corporation which has 35+ years in the plastic & metals manufacturing
business.
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
About TTE – Gemini Group
• Processes of Gemini’s largest customers, 9 out of 10 purchase product from two or more of our
processes.
• One networked company, endless possibilities.
Plastics
• Compression Molding
• Vacuum Forming
• Thermoforming
• Blow Molding
• Profile Extrusion
• Injection Molding
Metals
• Precision Machining
• Precision Tool holders
• Production Machining
• Aluminum Extrusion Tooling
• Die Cast Tooling
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Overview
• We use HyperXtrude to test new designs and theories.
• We also use HyperXtrude to aid in our die rework process.
• The information that is collected is then incorporated into future designs.
• We are able to test die corrections without having to ship the die back to the customer and have
them run another trial on the die.
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Die #3902
• This is extrusion die for a rectangular bar using harder alloy(AA6082)
• Profile shape is wider compared to metal entry area
• This die was built without being simulated
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Pre-processing – HyperXtrude - 2015
• Few mouse clicks to setup whole model
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Both ends of the extruded part ran fast and causing the profile to be out of contour
• This simulation results matched with the actual extrusion
Design #1
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design #2
• The die#1 was returned
• Slight changes were made in the
die
• The changes in die did not
improve the contour.
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design #3
• The die was returned 2nd time
• We simulated several changes in die
to speedup the flow in central region
of die by making it a wider opening
• Once we got the results we were
looking for, we made changes to the
die tooling
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design #3
• The final correct die ran great and the contour was perfect.
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Die #Cobr
• Extrusion of large U shape profile in 14” container
• This die was built without being simulated
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Pre-processing – HyperXtrude - 2015
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design #1
• This simulation results are from the first die trial run.
• One side of profile is coming faster compared to other side
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design #2
• The die was returned for correction
• We simulated several changes
• Once we got the results we were looking for we made changes to the tooling
• The die ran great and after it going the top of the channel caught up with the tips
Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Summary
• All the die trials can done virtually using HyperXtrude
• We are able to test die corrections without having to ship the die back to the customer and have
them run another trial on the die.
The HyperXtrude – 2015 interface has allowed us to move away from a dedicated user