Product Overview:
In this tutorial, we conduct a simulation of the three-dimensional cold extrusion process of an aluminum rod using Abaqus. Both the aluminum rod and the die are modeled as three-dimensional solid parts.

Key Features of the Simulation:

• Material Properties: The aluminum rod is treated as an elastic material with temperature-dependent plasticity. Important thermal properties such as conductivity, specific heat, expansion coefficient, and inelastic heat fraction are incorporated, given the thermally coupled analysis used in the simulation.
• Analysis Approach: A fully coupled temperature-displacement analysis is conducted while maintaining the die at a constant temperature. Additionally, an adiabatic analysis is performed using Abaqus/Standard, ignoring any frictional heat generation.
• Contact Formulations: The simulation employs both node-to-surface (default) and surface-to-surface contact formulations in Abaqus/Standard.

Simulation Steps:

1. Contact Establishment: Initial setup to define contact between the rod and die.
2. Extrusion Process: The actual cold extrusion process is simulated in this step.
3. Contact Removal: After extrusion, contacts are removed to analyze the subsequent effects.
4. Cooling Process: Finally, a cooling process is applied, with convection conditions set for the outer surfaces of the aluminum rod.

For the contact properties, surface-to-surface interactions including friction and heat generation are selected, while fixed boundary conditions are assigned to the die and displacement conditions to the rod. A fine mesh is crucial to ensure accurate results.

After completing the simulation, various outputs such as stress, plastic strain, and temperature are generated.