I am currently working on simulating the post-extrusion stretching process of aluminum profiles to better understand deformation during stretching and reduce production scrap.

The objectives of this study are to,

* Predict profile offcut variation under different stretching forces.

* Evaluate the influence of vertical jaw clamping force.

* Understand how profile bending propagates during stretching.

* Optimize stretching parameters to minimize offcuts and improve material utilization.

* Estimate production capability and scrap rates for different profile geometries.

* Ultimately, use these findings during the die design stage so that stretching jigs and their costs can be considered early in product development.

What I have Tried,

I first modeled the complete stretching assembly in SOLIDWORKS Simulation, including the steel jaws and aluminum profile.

The setup included,

* Fixed lower jaw

* 50 kN clamping force on the upper jaw

* Tensile loading to simulate stretching

* Coincident mates between the jaws and profile to prevent separation

However, this resulted in unrealistic behavior. The coincident mates restricted the model, causing local edge crushing, unrealistic load transfer, and unsuccessful simulation results.

To simplify the problem, I modeled only the aluminum profile and replaced the jaws with equivalent boundary conditions.

* 50 kN compressive load representing the upper jaw

* Fixed regions representing the lower jaw

* Tensile load applied to one end of the profile

Although this eliminated contact issues, the results were still unrealistic, with extremely high localized stresses and deformation patterns that did not match the actual stretching process.

Looking for Your Expertise

I would really appreciate advice from engineers experienced in FEA, CAE, and aluminum extrusion.

* Is SOLIDWORKS Simulation capable of accurately simulating this type of stretching process?

* Should this be modeled using nonlinear analysis with large deformation, frictional contact, and material plasticity?

* How would you model the gripping action of serrated stretcher jaws without introducing unrealistic stress concentrations?

* Would displacement-controlled loading be more representative than force-controlled loading?

* Are there any papers, tutorials, or industrial best practices you would recommend?

Any suggestions, references, or shared experiences would be greatly appreciated. Thank you in advance for helping me improve this simulation and better understand the stretching behavior of aluminum extrusion profiles.