Abstract:The finite element method (FEM) and the finite volume method (FVM) numerical simulation methods have been widely used in forging industries to improve the quality of products and reduce the costs. Because of very concentrative large deformation during the aluminum extrusion processes, it is very difficult to simulate the whole forming process only by using either FEM or FVM. In order to solve this problem, an FEM and FVM compound simulation method was proposed. The theoretical equations of the compound simulation method were given and the key techniques were studied. Then, the configuration of the compound simulation system was established. The tube extrusion process was simulated successfully so as to prove the validity of this approach for aluminum extrusion processes. 

Key words:  FEM; FVM; compound simulation; aluminum extrusion