Numerical simulation study of effect of die structure on the extrusion deformation of FGH4096 alloys

A combination of finite element numerical simulation software and orthogonal experiment was used to study the hot extrusion process of FGH4096 alloys. The influence of die angle, entrance fillet radius, and working belt length on the effective strain distribution, temperature distribution, and extrusion load of the extruded products was systematically analyzed. The results show that, with the increase of the die angle, the effective strain distribution area decreases, the extrusion load increases, and the temperature rise effect is serious in the extrusion process. The smaller the die angle, the lower the extrusion load, and the effect of temperature rise in the core of the extruded products is reduced, but the area of effective strain less than 1.500 in the core increases. The radius of the inlet fillet and the length of the working belt have little effect on the effective strain distribution, temperature distribution, and extrusion load in the extruded product. When the die angle is 45°, the area with the uniform effective strain distribution increases and the effective strain distribution becomes more uniform. The extrusion die was made for the simulation experiment verification. In the result, the actual extrusion process and the numerical simulation data are consistent, proving that the simulation parameters are set reasonably, which has the guiding significance for the practical production.