ALex & 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 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. Consequences 1. 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)

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/mm 2 Die Preheating Temperature: 470 °C Billet Preheating Temperature: 530 °C Medium RAM Speed: 1 mm/sec HyperXtrude ® 8.0

Results Analysis

Butterfly Die ®