ALex 2007 - 13 & 14 November 2007, Eindhoven

Butterfly Dies®

Increase Extrusion Speed through

Innovative Porthole Die Design

Mr Tommaso Pinter, ALMAX-MORI (Italy)

Overview Features Applications Overview Qualitative Analysis Developments

Schedule (15’)

1. Almax & Alumat Group Since 1965 Sales for 14.000 K€/year

2. Butterfly Die Porthole Die Introduced in Italy in the 90’s Butterfly Die™

Applied to 30% of new projects

Overview

Effective architecture 1. Bigger feedings;2. Better feeding of the exteriors and concealed parts;3. Better support against mandrel flections.

Consequences1. More stability and less mandrel movements;2. Less working pressure/temperature;3. Higher extrusion speed;4. Longer Die Life.

Final Goal: Higher Press Productivity

Features

Applications

Case Study (1/3)

7’

Case Study (2/3)

Comparison - Working Pressure

0

50

100

150

200

250

0 20 40 60 80 100 120 140

Time [sec]

Pre

ssu

re [b

ar]

Butterfly Construction Traditional Design

Case Study (3/3)

Ram Speed: 8 mm/sec

Ram Speed: 6 mm/sec

Developments: 3D CAM

Courtesy of Aleris

Aluminum Bonn

Developments: 3D Simulation

1. 2D Die Design

2. 3D Solid Model

3. Aluminium Model & FEM Generation

4. Set Up of Process Parameters & Boundary Conditions

5. Simulation Run & Process Interpretation

1. Process Parameters Direct Extrusion Container Diameter: 500 mm Alloy: 6082 Nominal Profile Weight: 21.4 Kg/m

2. Hypothesis Not Flexible Die Adiabatic Process

3. Boundary Conditions Press Specific Pressure: 46 Kg/mm2

Die Preheating Temperature: 470 °C Billet Preheating Temperature: 530

°C Medium RAM Speed: 1 mm/sec

HyperXtrude® 8.0

Results Analysis

World Tarde Center - Dubai

www.almax-mori.it

Butterfly Die®