Abstract: The extrusion process of a thin-walled hollow aluminum alloy profile with small features is simulated by using arbitrary Largrang-Euler(ALE) algorithm based HyperXtrude software. The material flow velocity standard deviation in the exit of the die hole is used as a criterion to evaluate velocity uniformity. By designing a series of baffle-blocks, the material flow velocity and the deformation of extrudate are controlled effectively. Effect of baffle-blocks on velocity uniformity is analyzed and a design method of baffle-blocks is proposed. The simulation results demonstrate that the section shapes of baffle-blocks play a key role in controlling material flow velocity in exit. When baffle-blocks have a reasonable section shape, material flow velocity and the deformation of extrudate can be controlled effectively and qualified profiles can be gained by adjusting height and distance between baffle-blocks and mold hole. In a certain range of the baffle-block’s height, the increase of the height of baffle-block can increase the uniformity of the materials flow velocity effectively. However, the increase of the width of baffle-blocks may not work on the balance of material flow material.

Key words: Aluminum alloy, Extrusion die, Flow velocity, Numerical analysis