Numerical and Experimental Analysis of Profile Complexity in Aluminum Extrusion

Josiah Cherian Chekotu, Sayyad Zahid Qamar*, Sayyad Basim Qamar

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Citation (Scopus)


In extrusion, shape complexity serves as an indicator of the difficulty in extruding the profile. It can affect the extrusion load and metal flow pattern. Non-homogeneous metal flow and severe pressure conditions can directly influence product quality, die life, and overall productivity. Most of the product defects can be linked to extrusion pressure and flow pattern of the metal. The current paper investigates, experimentally and numerically, how shape complexity influences extrusion load and material flow. Finite element modelling (FEM) is used to simulate and analyze the cold extrusion of various die shapes (nine) having distinct profile complexities. Generated numerical solutions are used to study the influence of geometrical complexity, extrusion ratio, and profile symmetry on dead metal zone (DMZ), metal flow, and extrusion pressure. All of these factors can aid in assessing the possibilities of certain types of product defects. It was observed that higher shape complexity values result in higher pressures and more severe metal flow patterns, which lead to higher chances of product defects. The findings of this study can be of assistance to die manufacturers and extrusion plants in optimizing the die designs, and reducing metal flow related defects.

Original languageEnglish
Title of host publicationProceedings of the 9th International Conference on Fracture, Fatigue and Wear - FFW 2021
EditorsMagd Abdel Wahab
PublisherSpringer Science and Business Media Deutschland GmbH
Number of pages9
ISBN (Print)9789811688096
Publication statusPublished - 2022
Event9th International Conference on Fracture, Fatigue and Wear, FFW 2021 - Virtual, Online
Duration: Aug 2 2021Aug 3 2021

Publication series

NameLecture Notes in Mechanical Engineering
ISSN (Print)2195-4356
ISSN (Electronic)2195-4364


Conference9th International Conference on Fracture, Fatigue and Wear, FFW 2021
CityVirtual, Online


  • Extrusion pressure
  • Metal extrusion
  • Metal flow
  • Product defects
  • Shape complexity

ASJC Scopus subject areas

  • Automotive Engineering
  • Aerospace Engineering
  • Mechanical Engineering
  • Fluid Flow and Transfer Processes


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