Inspire Extrude Extrusion Simulation

Standard Operating Procedure

Simulation Preparation

Extrusion Die

To run an extrusion simulation in Altair Inspire Extrude (IE), you will need to have a CAD model of the die you wish to analyze. Your simulation is more likely to run successfully if you do the following things:

1. Save the file the die’s model as a .stp file to be imported into Inspire Extrude.
2. Create a folder in your Michigan Tech H-Drive (home drive) to save all die models and Inspire Extrude files.
3. Ensure model is fully constrained to avoid meshing issues while modeling.

Obtain Press & Process Information

Below is the information prompted by IE to model an extrusion press that is not one of the pre-set presses. The values are for MTU’s Breda 550 Extrusion Press; if you wish to model a different press, you will have to obtain new information Container Diameter: 3.7 inches Maximum Billet Length: 10 inches Minimum Billet Length: 2 inches Maximum Ram Speed: 30 in/min Maximum Extrusion Ration: 100:1 Maximum Exit Velocity: default Max Taper per Length: 10C to 20C Press Capacity: 550 tons Dead Cycle Time: 60 seconds

Running an Extrusion Simulation

Figure 1 – “Extrusion” Tools avaible for Inspire Extrude users.

To begin a simulation, open your die’s .stp file into the program; it should appear in the program’s window. The ‘Open” command can be found in the “File” tab of the tool menu. Like more Altair programs, setting up a simulation in IE is relatively straight forward if you work left to right across the top tool bar. This section will break down how to use and maneuver each IE tool bar icon.

Orientation

1. Click on the “Orientation”.
2. Use the axis to appears to assign the direction the metal should exit the die.
   • The positive z axis should align with this direction.
3. Right click in an open area of the work screen and click the green checkmark to end task.

Flow Volume

1. Click and drag to highlight your entire die model.
2. Click on “Flow Volume”.
   • This will determine the space avaible in your die for metal to “flow” through during extrusion.
   • This step may not work if there are gaps in your die assembly
3. Right click in an open area of the work screen and click the green checkmark to end task.

Bearing

1. Hover over the “Bearing” icon until the _____ (____) is highlighted. Select this feature.
2. Use your cursor to highlight the bearing surface on the flow volume shown in the workspace.
3. After this, a small entry box should pop-up asking for the following information:
   • Bearing Length: enter the correct bearing length according to your die dimensions.
   • Profile Length: enter the length of extrusion you want the program to execute.
4. Right click in an open area of the work screen and click the green checkmark to end task.

Organize

If your die has multiple parts, this step will be needed to help the program assign the different parts of your model. The avaible options are: .

Billet

1. Click on the “Billet” icon; a pop-up menu should appear.
2. Enter appropriate billet dimensions.
   • MTU uses 3.5’’ diameter billets.
   • DO NOT CLICK SKIN THICKNESS. You will have to restart your model.
3. Right click in an open area of the work screen and click the green checkmark to end task.

Materials

Inspire Extrude has a large data base of avaible billet, die, and coolant materials. A SOP for how to add a custom material will be added here soon.

1. Click on the “Materials” icon.
2. The menu on the upper-left side of the pop-up screen will show which part of the extrusion you are currently selecting materials for (billet, die, or coolant). The menu on the lower-left side will show you what materials you have selected for each part; you can add or remove selections here by right clicking and pressing “Remove/Delete”.
3. Click through material library to select your billet material.
4. Click “Tool Material” in the upper left menu and then select your tool material.
   • MTU uses H13 tool steel for their dies.
5. Right click on the coolant material in the lower-left menu; MTU’s foundry does not use a coolant for extrusions.
6. Once all material settings are correct, press “Okay” to apply the settings.

Press Data

When you press “Press Data”, Inspire Extrude will show you three options: two pre-set presses and a “user” press. The “user” press is where you can create your own press to model with.

1. Click the “Edit” button and enter in press specifications.
2. Click “Apply”
3. Make sure your new press data is selected and then click “Okay”.