J. Cent. South Univ. Technol.

(2008) 15(s2): 357−361

DOI: 10.1007/s11771−008−0487−8

Conformal optimal design and processing of extruding die cavity

QI Hong-yuan(齐红元)1, CHEN Ke-shan(陈科山)1, DU Feng-shan(杜凤山)2

(1. School of Mechanical and Electric Control Engineering, Beijing Jiaotong University, Beijing 100044, China;
2. School of Mechanical Engineering, Yanshan University, Qihuangdao 066004, China)

Abstract: Aimed at the optimal analysis and processing technology of die cavity of special-shaped products extrusion, by numerical
analysis of trigonometric interpolation and Conformal Mapping theory, on the non-circle cross-section of special-shaped products,
the conformal mapping function can be set up to translate the cross-section region into unit dish region, over numerical finite
interpolation points between even and odd. Products extrusion forming can be turned into two-dimension problem, and plastic stream
function can be deduced, as well as the mathematical model of the die cavity surface is established based on deferent kinds of vertical
curve. By applying Upper-bound Principle, the vertical curves and related parameters of die cavity are optimized. Combining with
electrical discharge machining (EDM) process and numerical control (NC) milling machine technology, the optimal processing of die
cavity can be realized. Taking ellipse-shaped products as an instance, the optimal analysis and processing of die cavity including
extruding experiment are carried out.

Key words: extrusion; forming; electrical discharge maching; die cavity; vertical curve; Conformal Mapping

difficult to geometrically descry be the die cavity contour

1 Introduction
The quality and power dissipation of special-shaped
extruding products are affected by many factors, one of
them is how to find out the optimal vertical-curve of die
cavity. Nowadays, the general vertical curves of die
cavity include linear, convex and concave, and
tri-streamline. The curves selection is so important that
the die geometrical profile and processing technology,
metal plastic flow, harden performance, material shaping
quality and lubricant are influenced, i.e., surface
disfigurement of the products such as scale crackles will
occur if an unsuitable vertical curve was selected[1].
For special-shaped products, the deforming process
is more complicated[2], and the calculation of three-
dimensions’ forming is even difficult, as a result, related
studies made few progress, no existed generalized
expression can be used to optimize the vertical curve of
die[3−5], even if some results were reported, all the results
focus on the individual specific special-shaped product,
but cannot be used in the die cavity modeling of random
special-shaped products[6−7].
At present, the general processing technology of
extruding die cavity includes electrical discharge
machining (EDM)[8], electrolytic girding, and NC milling
machine technology[9]. Though some numerical methods
exist, such as Beserl and B-Spline methods, it is still
with partial special curve, so that its die cavity contour
optimization cannot be realized, and its exact processing
technology can not be developed as well. In this paper,
three-dimension plastic flow problems were translated
into two-dimension problems with the application of
Numerical Complex Mapping theory[10−11]. Furthermore,
by Upper-bound Principle[12], the comparisons among
three kinds of die cavity, namely convex, linear and
streamline were completed. With the help of EDM
process and NC milling machine technology, the
processing of optimal die cavity can be realized. Taking
ellipse-shaped product forming as an instance, the
vertical curve comparisons and parameters optimization
of die cavity were carried out.
2 Die cavity Conformal Mapping
By Complex Conformal Mapping theory, the
complex region mapping in Fig.1(b) was turned into unit
dish region in Fig.1(a), the mapping function of complex
polynomial can describe the geometrical region on the
cross-section of complex die cavity as follows
∞
W = ∑ c n ζ n (ξ=ρexp(iθ)) (1)
n =0
where cn=an+ibn is complex coefficient, mapping
function W should satisfy the following boundary conditions

Foundation item: Porject(50075076) supported by the National Natural Science Foundation of China; Porject(2007XM036) supported by Science and
Technology of Beijing Jiaotong Uniersity, China
Received date: 2008−09−05; Accepted date: 2008−10−18
Corresponding author: QI Hong-yuan, Associate professor, PhD; Tel: +86-10-51682997; E-mail: hyqi@bjtu.edu.cn
358 J. Cent. South Univ. Technol. (2008) 15(s2): 357−361

3 Die cavity modeling

Vertical curve function f(z) of die cavity is the

important function in calculating the metal plastic flow,
die cavity modeling, and optimizing the length L of
deforming region. As shown in Fig.2, at the inlet and exit

Fig.1 Conformal mapping between complicated region and unit

dish: (a) Complicated region; (b) Unit dish

W = f (ζ ) ζ =0 = 0 (2)

Over Eqn.(2), Eqn.(1) can be described by Complex

trigonometric function as follows
⎧ ∞
⎪
⎪
x ( ρ , θ ) = ∑ c n ρ n cos nθ
n =1 (3)
⎨ ∞ Fig.2 Surface of extruding die cavity
⎪ y ( ρ , θ ) = c ρ n sin nθ
⎪⎩ ∑ n
n =1
of die cavity, the geometrical boundary conditions in
where ρ and θ are module and phase of random vector which f(z) selects to satisfy is
in Fig.1(a).
As shown in Fig.1, assuming the boundary f(z=0)=1; f(z=L)=0 (5)
Wk=xk+iyk of complicated region W are interpolation
When the vertical curve of die cavity belongs to
points, k ∈ N (positive integer), and xk and yk are real part
linear shape, the curve function f(z) is given by
value and imaginary value of Wk. By mapping function
W, the mapping points of Complex vector W1, W2, ···, Wn z
f ( z) = − +1 (6)
are 1, 2, ···, n respectively as shown in Fig.1(a). L
Supposing that the phases θk ∈ [0, 2π] of complex vectors
When the vertical curve of die cavity belongs to
1, 2, ···, n are arithmetical progression, put W1, W2, ···, Wn
convex shape, the curve function f(z) is gotten as follows
coordinate points (interpolation points) values into
Eqn.(3), when n is large enough, the infinite interpolation z
points in Eqn.(3) can be replaced by limited interpolation f ( z) = − +1 (7)
L
points. From the orthogonal character of trigonometric
function, the values of the real part aj and imaginary part When the vertical curve of die cavity belongs to
bj of complex coefficients cj in progression function of tri-streamline shape, the curve function f(z) is given by
limit n ∈ N can be obtained
f ( z ) = Az 3 + Bz 2 + Cz + D
⎧ 1 m
⎪a j = ∑ [x k cos( jθ k ) + y k sin( jθ k )] It will satisfy not only the geometrical boundary
⎪ n k =1
⎨ m
(4) conditions in Eqn.(3), but also the plastic flow conditions
1
⎪b =
⎪⎩ j ∑ [− x k sin( jθ k ) + y k cos( jθ k )] at the inlet and exit of die cavity
n k =1
where interpolation points W1, W2, ···, Wm are unknown df ( z ) df ( z )
=0, =0 (8)
values satisfying boundary mapping conditions. The dz z =0 dz z =L
interpolation points can be defined as odd interpolation
points when the interpolation points cannot satisfy the Therefore
calculating precision requirement. Adding new z3 z2
interpolation points between the odd interpolation points, f ( z) = 2 −3 +1 (9)
L3 L2
namely even points, then doing mutual iterative
calculation, interpolation point value and cn value can be If f(z) is computed and united with Eqn.(1), the
calculated under the condition of satisfying calculating parameter function of three-dimension die cavity surface
precise[13]. can be set up as follows
J. Cent. South Univ. Technol. (2008) 15(s2): 357−361 359
separately, vS(ρ=1) represents the relative velocity between
⎧ N
⎪ x = Ri f ( z ) cos θ + [1 − f ( z )] ∑ c n cos nθ the surface of metal and die cavity, m is friction factor.
⎪ n =1 From Metal Plastic Upper-bound Principle, the general
⎪ N
⎨ y = Ri f ( z ) sin θ + [1 − f ( z )] ∑ c n sin θ (10) power dissipation J*(L) in the metal plastic deforming
⎪ n =1 region is the sum of deforming power dissipation in the
⎪ metal deforming region and shearing power dissipation
⎪ z=z ( 0 ≤ z ≤ L, 0≤θ ≤2 π, 0≤ ρ ≤1)
⎩ on surfaces Si and So, and the friction power dissipation
To sum up, by using Conformal Mapping and the on surface S, J*(L) are gotten as follows
methods of numerical mutual interpolation points J*(L)= ∫∫∫ ε&σ S dV + k ∫∫ v z =0 dS i + k ∫∫ v z = L dS o +
between even and odd to calculate cn, die cavity V
modeling of precise extrusion (when ρ=1) is completed. σS
Combining with EDM process and NC milling machine mk ∫∫ vS( ρ =1) dS (k = ) (15)
3
technology, the processing of the optimal die cavity can
be realized. Suppose that：

J ∗ (L )
4 Metal plastic flow field P= (16)
A0V0σ S
As shown in Fig.2, Sz, vi are random cross-section where P is related pressure ratio. Asking P for extreme
area of metal die cavity and plastic flow velocity along z in Eqn.(16), the optimization of parameter L of extruding
axial direction at the inlet of billet. Assuming that the die can be realized.
velocity along z axial direction is even distributed on the
random cross-section vertical to z-axis, thus 6 Example and discussion
Si
vz = vi (11) Assume that the billet is rod whose diameter is 30 mm,
Sz
the major axis of ellipse-shaped product is 28 mm, and
Two surface functions of plastic flow of special- minor axis is 2b=18 mm. Over the iterative calculation
shaped products are given by between odd and even (N=32 interpolating points are
ρ(x, y, z)=Constant; θ(x, y, z)=Constant (12) taken randomly, which represents the infinite points of
Eqn.(1) in the first quadrant), hence xk, yk and c n can be
In deforming region, the plastic flow velocity
computed
vectors along x, y, z axial directions are vx, vy, vz
xk ={000,13.432 26, 12.226 84, 10.930 31, 9.710 11,
respectively. Plastic deforming stream functions on the
8.593 57, 7.572 86, 6.632 53, 5.758 83, 4.938 78, 4.161
surface of die cavity are given by total differential of
44, 3.420 54, 2.706 09, 2.012 22, 1.333 43, 0.664 30,
Eqn.(12) based on ρ and θ at the two random flow
0.000 000}
surface separately as follows[14]
yk={00000, 2.539 11, 4.383 02, 5.624 25, 6.483 13,
vx vy vz 7.105 18, 7.569 55, 7.926 03, 8.203 26, 8.421 46, 8.593 29,
= = (13)
∞ ∞ 1 8.727 24, 8.830 26, 0.890 656, 0.895 908, 8.989 86,
− ∑ An ( z)ρ cos n θ
' n
− ∑ An ( z)ρ sin nθ
' n
9.000 00}
n=1 n=1
a2j−1={1.316 552, 0.073 814, 0.007 726, 0.001 113,
where A1 ( z) = Ri f ( z) + a1[1 − f ( z)] , 0.000 699, 0.000 065, −0.000 570, −0.000 035, 0.000 695,
0.000 043, −000 093 0, −0.000 056, 0.001 448, 0.000 087,
An ( z ) = a n [1 − f ( z )] (n=2, 3···N).
−0.003 114, −0.000 186};
By plastic deforming theory, the strain velocity is a2j=0; b2j= b2j−1=0 (j =1, 2, ···, 16)
calculated by[10] Bring the above parameters into Eqn.(16), the die
. 1 ⎛⎜ ∂ v j ∂ vi ⎞ cavity function Eqn.(10) can be given by asking
ε ij = + ⎟ (14) optimized length L. As shown in Fig.3, under the same
⎜
2 ⎝ ∂ xi ∂ x j ⎟
⎠ conditions of press ratio λ=0.56 and friction factor m=0.3,
the parameters of die, L=13.1 whose vertical curve Eqn.(7)
5 Die cavity optimization is convex, L=14.2 whose vertical curve Eqn.(6)is linear,
and L=17.2 whose vertical curve Eqn.(9) is streamline
Suppose ε (ρ, θ, z) is equivalent strain ratio, σs can all be calculated. The power dissipation in Fig.3
represents the metal yield stress, V is the space volume of shows the decreasing tendency due to the vertical curves
deforming body, k is shearing yield ratio, v(z=0), v(z=L) are changing from convex, linear and streamline, which
velocity discontinuity at the inlet and exit of die cavity demonstrates that the material plastic flow is the flattest
360
Fig.3 Optimized parameter L of dies curve
during the process of streamline die deforming. Thus, the
streamline die should be the first selection to guarantee
the quality of extruding products when the die cavity
processing technology is available. Meanwhile, it
concludes that the die cavity whose vertical curve is
linear is optimal comparing with that of convex by power
analysis. Fig.4 represents the die cavity profile whose
vertical curve is streamline.
Fig.4 Optimized profiles for die cavity
J. Cent. South Univ. Technol. (2008) 15(s2): 357−361
7 Streamline die processing
By applying EDM technology, Ellipse-shaped
products die can be manufactured over model Eqn.(10).
However, EDM requires the production of electrodes
whose negative shape is eroded by the process. Generally,
two electrodes are used to produce each of the extrusion
die cavity by means of a NC milling machine and these
are later polished to provide finer surface finish.
In order to obtain the designed dimension of
streamline die cavity of ellipse-shaped products during
experimental extrusion, the dimension of produced
electrode is somewhat smaller than that of the actual
dimension of the die cavity due to the allowance given in
EDM. The allowance is determined by the machining
gap thickness and the surface finish parameters.
Electrodes are designed and programmed by model
Eqn.(10) and CAD/CAM of Unigraphics (UG) software.
The experimental die is processed as shown in Fig.5. In
Fig.6, the extruding grid parts (2a=28 mm and 2b=18
mm) satisfying the precise requirements are machined.
Fig.5 Photo of extruding die
Fig.6 Photo of experimental part
8 Conclusions
1) By Conformal Mapping theory, the mathematical
three-dimension models of extruding die cavity surface
whose vertical curves are linear, streamline, and convex
were set up.
J. Cent. South Univ. Technol. (2008) 15(s2): 357−361
2) The die cavity whose vertical curve is
tri-streamline is optimal compared with that of convex,
and linear die cavity is better than that of convex.
Combining with the electrical discharge machining
(EDM) process and numerical control (NC) milling
machine technology, the processing of the optimal die
cavity can be realized.
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(Edited by LONG Huai-zhong)