A. Hosseini Hashemi - M.s student of mechanic Eng - Manufacturing Engineering Group, Mechanical Engineering Department, College of engineering, University of Tehran, Tehran, Iran
K. Abrinia - Associate Professor - Manufacturing Engineering Group, Mechanical Engineering Department, College of engineering, University of Tehran, Tehran, Iran
M.K Besharati - Associate Professor - Manufacturing Engineering Group, Mechanical Engineering Department, College of engineering, University of Tehran, Tehran, Iran

Aluminum and alloys of aluminum have a wide application in Aerospace industries. There are many methods for production of aluminum objects. Such these methods, is the extrusion. Dead zone is the main problem in the aluminum extrusion molds because it makes pressure high and final objects from extrusion process have bad surface roughness. In this article presented a new method for simulation and prediction of dead zone in extrusion molds. This simulation is based on shear damage theory that it’s gotten from ductile metal theory. Shear damage is the main reason for creating dead zone in extrusion molds so we can optimize these molds without dead zone problem then we can produce aluminum objects with best quality. This mold analyzed with Dynamic Explicit in ABAQUS.CAE software after deleting those elements with shear damage between 0.8 to 1 the new boundary was appeared then with new boundaries of result contours, the new optimized mold was designed. This optimized mold shows some valuable results such these; extremely reduce in working pressure and best surface quality on final extrusion objects. Experiment tests are showing the exactitude of this new method results. This method can use directly to other extrusion molds.

Dead zone, Fracture energy, Shear module