Streamline approach to die design and investigation of material flow during the vortex extrusion process

• Mathematical modeling of the material flow in vortex extrusion (VE).
• Investigation of material flow in VE process.
• VE die design based on the proposed model.
• Predicting of process load based on proposed model.

In this study, a streamline approach based on a cubic Bezier formulation is used to investigate the material flow during vortex extrusion (VE). The velocity field and upper bound terms are calculated based on the proposed mathematical model in order to estimate the process load. The VE dies designed according to the proposed mathematical model are used for finite element analyses of the VE process in order to investigate the effect of various processing parameters on the strain distribution and process load. Comparisons of the simulated results with those obtained from the upper bound analysis demonstrate that the load increases in the VE process as the twist angle increases. Furthermore, we demonstrate that reducing the twist zone length and increasing the friction improve the material twisting during the VE process.