Hello,

First of all I'm new here so I hope I'll do everything as it should be and I'll try to give you enough information.

I'm trying to create a simulation model for an extrusion.

I have two parts: a die and a shaft.

The material of the die is some high strentgh steel, the material of the shaft is aluminum.

The extrusion will be from 3.9 mm to 3.2 mm.

The purpose of the study is to get the force that will be needed for the extusion.

The shaft has to be plastic deformed and the die only elastic.

The material for the shaft is set on Plasticity Von Mises with Etan set on: 75500 MPa (A higher value as the Emod. otherwise I

get this error: "Incremental plastic strain is too large"

I guess the Etan has to be around 10% of the Emod but I'm not sure.

For contact set I've selected the outside of the shaft and the inside of the die. (No friction)

Advanced contact settigs: Surface to Surface

The bottom of the die is Fixed.

Both Planes are set to symmetry fixtures.

The shaft has a diplacement downwards of 6.4 mm so the top planes of both parts will be equal.

I've set up a time curve this way:

When the displacement is returned to it's origin I would like that the part is still deformed.

But that isn't working.

I've created a coarse mesh with a mesh control on the outside of the shaft and the inside of the die.

These are the settings I've used in the study properties:

Results:

The volume of the shaft is the same as the open volume in the die so I don't understand why the shaft don't fill up the die.

I understand that the die will deforme a bit as I can see when I plot the displacement in Z. But that isn't that much.

I hope someone can help me with this.

Thanks in advance.

Niels