Investigation of metal flow in bridge die extrusion of Alloy 6063 and subsequent effect on surface quality and weld seam integrity

This paper describes a detailed study of tube extrusion by simulation using finite element method (FEM). The finite element model used one-sixth of symmetry. The extrusion load, temperature evolution and metal flow were predicted. Innovative methods, combining both grid and surface tools, were used to define in detail the flow of material. These showed clearly the inner and outer surface formation mechanisms of the tube extrusion. The seam weld, an important quality indicator, was also evaluated by selecting an appropriate criterion.