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


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.


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


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.

Die #3902

Analysis and correction of die


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


Pre-processing – HyperXtrude - 2015

• Few mouse clicks to setup whole model


• 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


Design #2

• The die#1 was returned

• Slight changes were made in the

die

• The changes in die did not

improve the contour.


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


Design #3

• The final correct die ran great and the contour was perfect.

Die #Cobr

Analysis and correction of die


Die #Cobr

• Extrusion of large U shape profile in 14” container

• This die was built without being simulated


Pre-processing – HyperXtrude - 2015


Design #1

• This simulation results are from the first die trial run.

• One side of profile is coming faster compared to other side


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


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

Thank you for your time

ensuring extrusion product quality at die design stage

Documents

correction of die

die tooling

die corrections

altair engineering

die design stage

central region of die

final correct die

die rework process