Marco Schikorra, Michael Schomäcker, Thomas Kloppenborg, A. Erman Tekkaya:
In: Ninth International Aluminum Extrusion Technology Seminar 2008, Orlando, USA, S. 297-307


The application of composite extrusion to reinforce aluminum profiles with continuous reinforcing elements to increase strength, stiffness, and functionality is a promising production method for lightweight profiles, for example in aerospace engineering. Process control and detailed knowledge on how to embed the endless high-strength reinforcement wires is absolutely necessary to achieve an acceptable composite development and positioning. Due to the complex die design needed to feed a large number of wires during the extrusion of thin-walled and hollow profiles basic process experience is required. The paper shows numerical investigations based on finite element simulations as well as experimental investigations of several profile geometries to study the influencing parameters regarding the occurring stress level in the reinforcement, the material flow, the positioning of the reinforcing elements, and die design strategies. Based on these results, guidelines for tool and process design will be shown to increase the process stability regarding reinforcement cracking, insufficient composite quality and poor positioning even for complex profile shapes. Finally, numerical optimization of the die design and process parameters was included in the numerical investigations to optimize the material flow and the profile’s exiting speed.