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In massive forming processes like rolling or extrusion, metal alloys are deformed in a hot solid state with material flowing under ideally plastic conditions. Such processes can be simulated effectively using computational fluid dynamics, where the material is considered as a fluid with a very high viscosity that depends on velocity and temperature. Internal friction of the moving material acts as a heat source, so that the heat transfer equations are fully coupled with those ruling the fluid dynamics part. This approach is especially advantageous when large deformations are involved.

This model is adapted from a benchmark study. The original benchmark solves a thermal-structural coupling. The alternative scheme modeled here couples non-Newtonian flow with the heat transfer equations. In addition, because it is useful to know the stress in the die due to fluid pressure and thermal loads, the model adds a structural mechanics analysis to the other two.

A comparison between the available experimental data and the numerical results of the simulation shows good agreement. On the basis of the results from the simulation, the engineer can improve the preliminary die design by adjusting relevant physical parameters and operating conditions.