Finite Element Modelling of Hot Extrusion of TI-6AL-4V Alloy

Maziar Ramezani, Thomas Neitzert

Die design, FE simulation, hot extrusion, Ti-6Al-4V.

A finite element (FE) model is developed in this paper for simulating the direct extrusion process of Ti-6Al-4V alloy under isothermal condition. The model takes into account the heat generation due to plastic deformation of the billet as well as the frictional heat in the billet-tool interface. A series of simulations have been conducted to investigate the effect of key process parameters on stress and strain distribution, maximum ram speed and maximum pressure applied to the die. The FE model has been compared with a theoretical model and the results show good correlation in terms of predicting ram load. The developed FE model can be used for investigating direct extrusion and selecting appropriate die design parameters for the process.