Three‐dimensional finite element analysis for hollow section extrusion of a triply‐connected section using mismatching refinement with domain decomposition

The present work is concerned with three‐dimensional finite element analysis of the hollow section extrusion process using a porthole die. The effects of related design parameters are discussed through the finite element simulation for extrusion of a triply‐connected rectangular tubular section. For economic computation, mismatching refinement, an efficient domain decomposition method with different mesh density for each subdomain is implemented. In order to obtain the uniform flow at the outlet, design parameters such as the hole size and the hole position are investigated and compared through the numerical analysis. Comparing the velocity distribution with that of the original design, it is concluded that the design modification enables more uniform flow characteristics. The analysis results are then successfully reflected on the industrial porthole die design.