Extrusion Simulation

Extrusion Simulation creates software that models process feasibility, line throughput, and full-line material flow before physical production begins. The tool consists of eight modules covering process and capacity prediction, core cooling and quench simulation, and line balance and bottleneck identification. It targets extrusion line operators and planners who need to evaluate press matching, cycle behaviour, cooling performance, and station-level constraints.

Users can start by requesting a demonstration of the software through the company's request process. The website offers a direct link to request a demo, allowing potential customers to see the tool in action before committing. There is no mention of a formal ordering or licensing process beyond this demo request.

The software includes eight distinct modules, such as process and capacity prediction, core cooling and quench simulation, and line balance and bottleneck identification. Each module feeds into a single data chain that runs from a single profile to the whole line and its budget. This modular structure allows for detailed analysis of specific line components.

The software uses 3D full-line visualisation to show how a customer's profile travels the entire line at real cycle time. This includes press, quench, saw, cooling bed, ageing, stacking, and die-oven change included on equipment models built from real machines. The visualisation happens in the same engine as the process prediction module.

The software includes a core cooling and quench simulation module that follows the profile station by station as it cools along the run-out. It determines whether the quench is reached in time and can hold the rate the press is otherwise capable of, identifying cases where cooling is the real speed limit. This module is crucial for understanding thermal constraints.

The line balance and bottleneck module runs the full chain from billet to packing at station-level takt inside the same 3D scene. The constraining station identifies itself highlighted in red, showing capacity against demand and stating output in billet in, extruded, and finished tonnes. This helps plants argue about output metrics accurately.

The press configuration and timing module works out pump groups, oil routing, and action timing for a hydraulic press from the loading arrangement rather than reading off a fixed tonnage label. An existing schematic can be brought in and compared against the proposed configuration to ensure accuracy. This avoids assumptions based on fixed labels.

The layout module allows users to pick the equipment, set the order, and have the line lay itself out in 3D. This feature helps planners visualize the physical arrangement of the entire extrusion line before construction begins. It integrates with the other modules to provide a cohesive view.

The company states that results are model-based estimates intended for comparison and early-stage judgement. They explicitly note that these results do not replace die trials or on-site validation. This clarifies the scope and limitations of the software's predictive capabilities.

The software is described as a multi-line plant solution built in the software, allowing users to model actual output. It addresses the issue where an extrusion line is committed on paper and corrected on the shop floor. The tool aims to prevent expensive mistakes by simulating decisions before implementation.

The website mentions that decisions are often made from memory regarding tonnage, cycle time, and achievable output. The software replaces this with data-driven modeling, preventing wrong calls that stay invisible for months until they become expensive. This highlights the value of early-stage simulation.

The software includes a 3D full-line visualisation that shows work piling up between stations or the handling gap that only appears once the line is at rate. This feature helps planners see the flow dynamics that static layout drawings cannot show. It provides a dynamic view of the production process.

The official website of Extrusion Simulation is extrusionsimulation.com.

On Trustburn, Extrusion Simulation has a rating of 4 out of 5 based on 5 reviews.