Aluminum Extrusion Simulation Using Finite Elements

The complexity of an extrusion die profile is determined by its geometry. Various metrics such as the complexity index, shape factor, and form factor are used to quantify how geometric intricacy affects production cost, die life, energy consumption, product quality, and overall manufacturability. Bearing geometry plays a critical role at controlling metal flow and tool life in aluminum extrusion. In this study a simulation based investigation is performed to investigate the influence of bearing geometry on extrusion behavior using the finite element method. Two extrusion dies are examined. A single cavity die with uniform bearing geometry and a dual cavity die with controlled bearing geometry modification in one cavity. The results show that the bearing modification in the dual-cavity die causes severe flow imbalance, with exit velocity deviations. This imbalance leads to localized pressure amplification, increased thermal gradients, and stress concentration in critical die regions. In contrast, the single-cavity die because of the simple geometry, exhibits uniform flow, stable pressure evolution, and low tool stress. These findings demonstrate the high sensitivity of multi-cavity extrusion dies to bearing geometry and highlight the importance of simulation-driven die design for achieving balanced flow and improved tool performance.