Calculations and Simulations

Extrusion Force Calculations

[Figure 1] Table of Necessary Parameters

[Figure 2] Solved Equations for Force

The maximum extrusion force is 17.27 kgf. The force exerted by the motor is capable of extrusion as it outputs a constant torque with a force of 3200 ozf which is greater than the necessary extrusion force.

Maintaining Extrusion Ratio in Scaling

To maintain the constant extrusion ratio as required from the prototype requirements, a scaling factor of 6.2 should be used

Stress Simulations

Individual Part Simulation

Simulations are performed in Fusion 360 on individual components to test strength during extrusion. The material is assumed to be 6061 Aluminum Alloy and the Safety Factor is taken with respect to yield strength. The applied force is 3200 ozf or the maximum output force of the motor pinion combination.

[Figure 3] Stress Simulation on Extruder Frame and Die Holder with minimum Safety Factor of 6.777

[Figure 4] Stress Simulation on Rack with minimum Safety Factor of 3.341

[Figure 5] Stress Simulation on Die with minimum Safety Factor of 15

[Figure 6] Stress Simulation on Ram and Mandrel with minimum safety factor of 6.165.

Full Assembly Simulation

Boundary conditions include a fixed bottom plate on the frame and a sliding frictionless plane on the bottom of the rack. Load constrains include an applied 890N or 3200 ozf to the die, mandrel/ram, and rack teeth at pinion location. Assumptions are that all forces are in the extrusion direction which ignores the friction and deformation forces on the container.

[Figure 6] Full simulation on machine shows a maximum Safety Factor of 2.911

[Figure 7] Full simulation on machine focused on areas with a Safety Factor under 8 which reveals the rack is the weakest component of the machine

Since the minimum safety factor for yield strength is 2.911, It can be safely said that the machine will not experience stress past the yield strength at any point during extrusion.

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