Numerical simulation of flash formation in continuous rotary extrusion of copper

Flash formation in continuous rotary extrusion of copper results in 5–25% material losses and extra costs from scrap handling. Continuous shearing of the flash between stationary shoe and rotating wheel increases considerably machine loading and tool surface wear. In the present work realistic 3D finite element simulations were carried out to study the formation of flash in continuous extrusion of copper, using DEFORM-3D finite element software. The results of the numerical simulations show that the flash shape is highly dependent of the frictional conditions.