Failure analysis of a die used in aluminum extrusion made with tool steel

Aluminum profile production is a rapidly developing field today, with extrusion being one of the most popular manufacturing methods. Along with the rapid advancement of extrusion processes, it is also observed that the design and production of extrusion dies are being similarly improved. Numerous research and development efforts are conducted to achieve goals such as reducing scrap rates, enhancing the quality of the extrusion product, and improving the quality of the extrusion die. The extrusion process and die production can be significantly improved by identifying potential damages in advance through simulation tools and digital environments. In this thesis, the causes of damage occurring in a mandrel, made of hot-work tool steel and used for aluminum extrusion die sets, have been investigated. Through microstructural analyses and mechanical tests, it has been determined that the cause of the damage in the mandrel is due to design deficiencies. To address these deficiencies and prevent the recurrence of damage, the design of the mandrel component was reassessed and optimized using the finite element method (FEM). The optimized design was subjected to simulation analyses using the Altair Inspire Extrude Metal module, and the performance of the new design was examined in detail. Subsequently, the improved mandrel design was integrated into the production environment and included in the aluminum extrusion process at an extrusion facility. During this process, the performance and durability of the mandrel were observed, and results were validated through tests conducted under actual production conditions. The studies carried out within the scope of this thesis make significant contributions to understanding the sources of damage encountered in the aluminum extrusion industry and developing effective methods that can be implemented to prevent such damages. Moreover, this research demonstrates how FEM analyses and simulation techniques can be effectively utilized in die design and provides practical recommendations for enhancing quality, reducing costs, and increasing operational efficiency in industrial applications. This study aims to serve as a valuable resource for engineers and researchers in the aluminum extrusion sector.