A general methodology for bearing design in non-symmetric T-shaped sections in extrusion process

In this study, a general methodology has been developed to design the proper bearing in order to eliminate the curvature of the final product in extrusion process. Three smooth curved (advanced-surface) dies with non-symmetric T-shaped sections and different off-centricities have been studied. For each die, the proper bearing has been designed and physical and numerical modeling have been performed to validate the design. The design procedure is as follows: A formulation, based on Bezier curves, has been used to determine the exit velocity profile. Since the result of Bezier method is different from the actual velocity profile, the Chitkara corrective function has been modified and applied to improve the velocity field. A deviation function has been developed to measure the curvature of the final product in terms of the exit velocity field. Considering the obtained velocity field, the friction effects, and the geometry of the dies, the proper bearing for each die has been designed. Finally, numerical and physical modeling have been performed on the die-bearing combination. According to the results, the curvature of the final product was eliminated to a great extent.