Case Study: Conglin Group achieves longer extrusion die life and higher productivity with Altair HyperXtrude

Extending Extrusion Die Life Using HyperXtrude

Conglin Group, a manufacturer of aluminum extrusions, faced short die life and frequent failures when extruding hard and newer alloys because traditional die designs produced high stress concentrations and low productivity. To tackle this, Conglin used Altair’s HyperXtrude finite-element simulation to analyze material flow, stress distribution and predict die service life before physical tryouts.

Using Altair HyperXtrude, Conglin evaluated two die designs: Design I (two-component) showed a maximum mandrel stress of 2751 MPa and fractured after about 10 billets, while Design II (three-component with portholes), redesigned based on HyperXtrude results, reduced bridge mandrel stress to 1675 MPa (die cap ~722 MPa), did not fail after 100 billets and produced more than 10 tons of alloy. Altair’s HyperXtrude virtual tryouts and tool-deflection analysis extended die life, increased productivity and lowered production costs.

Conglin Group