Cavity defects occur in extruded products, especially in a relatively short, headed product when the remaining billet reaches a certain thickness. Such defects can be a serious problem in manufacturing because they produce waste material and require an extra operation for finishing. Therefore an understanding of the process of cavity formation is important. A virtual simulation of the development of the defect facilitates student understanding. This paper introduces a detailed explanation of cavity formation that uses a non-linear finite element method package, Abaqus. The simulation result shows the shape conditions during the extrusion process.
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