Transactions of Materials and Heat Treatment

Title：Optimization on extrusion die for multi-cavity double-layer coaxial aluminum alloy circular tube based on finite element analysis

Authors： Zhang Dejun1 Lin Chunmei1 Cao Shanpeng2 Sun Qiaoyan1 Li Jiabao1

Unit： 1.College of Intelligent Science and Engineering Yantai Nanshan University 2.Shandong Nanshan Aluminum Co. Ltd.

KeyWords： multi-cavity double-layer coaxial circular tube 6061 aluminum alloy extrusion die extrusion load die stress

ClassificationCode：TG146.2+1

year,vol(issue):pagenumber：2024,49(10):82-91

Abstract：

In order to reduce the extrusion deformation of multi-cavity double-layer coaxial 6061 aluminum alloy circular tube, the numerical simulation on the extrusion process of profile was carried out by software HyperXtrude, and according to the simulation results, the die structure was optimized by expanding the inner circular diversion cavity and adding a flow barrier to reduce the maximum and minimum velocity difference at profile outlet from 19.37 mm·s-1 to 1.37 mm·s-1 and the standard deviation of profile outlet velocity from 8.1 mm·s-1 to 0.31 mm·s-1, and improve the velocity uniformity at profile outlet greatly. Then, the comparative analysis shows that the metal flow in the optimized die is more uniform, the extrusion load and the die stress are reduced, and the temperature at profile outlet is slightly increased, which is beneficial to improving the mechanical properties of profile after online quenching. All parameters of the optimized die meet the requirements of the actual extrusion production in the factory. Finally, the qualified product are produced on a 30 MN extruder by using the optimized die structural dimension and simulated extrusion process parameters, which proves the reliability of the optimized die structure for aluminum alloy multi-cavity double-layer coaxial circular tube extrusion based on finite element analysis. Thus, the design experience is provided for the extrusion die design of multi-cavity double-layer coaxial circular tube profiles.

Funds：

山东省自然科学基金资助项目(ZR2020KE012)；烟台市科技创新发展基金资助项目（2023JCYJ055）；南山控股科技项目（2023-5-1）

作者简介：张德军（1980-），男，硕士，副教授,E-mail：zdjlcm@126.com;通信作者：曹善鹏（1987-），男，博士，高级工程师,E-mail：caoshanpeng@nanshan.com.cn

Reference：

[1]李冰,陈星合,付博文，等.7075铝合金线材连续流变挤压与双级时效热处理研究[J].稀有金属,2023,47(9):1195-1203.

Li B, Chen X H, Fu B W，et al. Continuous rheo-extrusion and double aging heat treatment of 7075 aluminum alloy wire[J]. Chinese Journal of Rare Metals,2023,47(9):1195-1203.

[2]王少华,刘惠,陈宗强,等.大型带筋薄壁圆管铝型材挤压成形数值模拟[J].锻压技术,2022,47(4):181-189.

Wang S H, Liu H, Chen Z Q, et al. Numerical simulation on extrusion forming for large ribbed thin-walled circular tube aluminum profile[J]. Forging & Stamping Technology, 2022,47(4):181-189.

[3]Guan Y J, Zhang C S, Zhao G Q，et al. Design of a multihole porthole die for aluminum tube extrusion [J]. Materials & Manufacturing Processes, 2012, 27(2): 147-153.

[4]Liu Z W，Li L X，Li S K，et al.Simulation analysis of porthole die extrusion process and die structure modifications for an aluminum profile with high length-width ratio and small cavity [J]. Materials，2018,11(9):1517.

[5]乔及森,郭策,许佳敏,等．基于人工神经网络的7075高强铝合金反向挤压工艺构建及优化控制策略[J].塑性工程学报,2023,30 (1): 11-17.

Qiao J S, Guo C, Xu J M, et al．Construction of optimization control strategy for indirect extrusion process of 7075 high-strength aluminum alloy based on artificial neural network[J]． Journal of Plasticity Engineering，2023，30 (1): 11-17.

[6]曾文浩,魏刚,邓小亮,等.长悬臂类空心铝型材挤压过程数值模拟及模具结构优化[J].塑性工程学报,2017,24(6):108-115.

Zeng W H,Wei G, Deng X L, et al. Numerical simulation of extrusion process and optimization of die structure for the hollow aluminum profile with long cantilever[J].Journal of Plasticity Engineering, 2017,24(6):108-115.

[7]王现君,苏楷,李圣普,等.基于HyperXtrude的铝合金型材挤压成形特性研究[J].热加工工艺,2022,51(11):102-104,108.

Wang X J, Su K, Li S P, et al. Research on extrusion forming characteristics of aluminum alloy profiles based on HyperXtrude[J]. Hot Working Technology, 2022,51(11):102-104,108.

[8]赵颖,运新兵,闫志勇,等.基于HyperXtrude的铝合金壁板连续挤压技术[J].塑性工程学报,2017,24(1):79-84.

Zhao Y, Yun X B, Yan Z Y, et al. Continuous extrusion technology of aluminum alloy panels based on HyperXtrude[J]. Journal of Plasticity Engineering,2017,24(1):79-84.

[9]Yi J, Wang Z H, Liu Z W, et al. FE analysis of extrusion defect and optimization of metal flow in porthole die for complex hollow aluminum profile[J].Transactions of Nonferrous Metals Society of China,2018,18（10）: 2094-2101.

[10]Truong T T，Hsu Q C，Canh T V, et al. A design approach of porthole die for flow balance in extrusion of complex solid aluminum heatsink profile with large variable wall thickness[J]. Metals,2020,10(5):553.

[11]邹照.双层多腔圆管铝型材挤压模具设计[J].轻合金加工技术,2020,48(7):20-23.

Zou Z. Design of extrusion die for double-layer multi-cavity aluminum tube[J]. Light Alloy Fabrication Technology, 2020，48(7):20-23.

[12]崔伟超.双层多腔铝合金圆管新型挤压模[J].轻合金加工技术, 2017, 45(10):36-39.

Cui W C. A new type of extrusion die for aluminum alloy tubes with double layers and multi cavities[J]. Light Alloy Fabrication Technology, 2017, 45(10):36-39.

[13]陈友鹏,陈洁,刘树坤,等.外镶嵌式大型水冷式铝合金电机外壳挤压模[J].铝加工,2023(1):59-63.

Chen Y P, Chen J, Liu S K, et al. Extrusion die structure for water cooled aluminum alloy motor shell [J]. Aluminum Fabrication,2023(1):59-63.

[14]高志玉,樊献金,窦春岳,等.特厚板厚度方向形变传递规律的仿真分析[J].钢铁,2019,54(4):49-54，62.

Gao Z Y, Fan X J, Dou C Y, et al. Simulation analysis on transfer law of deformation in thickness direction of ultra-heavy plate[J].Iron and Steel,2019,54(4):49-54，62.

[15]李剑.6061铝合金挤压速度优化研究[D].南昌：南昌大学,2023.

Li J. Research on Extrusion Speed Optimization of 6061 Aluminum Alloy[D]. Nanchang：Nanchang University,2023.

[16]Bakker A J D，Werkhoven R J，Sillekens W H，et al. The origin of weld seam defects related to metal flow in the hot extrusion of aluminium alloys EN AW-6060 and EN AW-6082[J]. Journal of Materials Processing Technology,2014,214(11)：2349-2358.

[17]李晓琳,魏峥.固溶温度对6061铝合金微观组织和力学性能的影响研究[J].热加工工艺,2019,48(24):144-146，152.

Li X L, Wei Z. Effects of solution temperature on microstructure and mechanical properties of 6061 aluminum alloy[J]. Hot Working Technology, 2019,48(24):144-146，152.

[18]刘国勇,郝鹏鹏,万里.基于HyperXtrude的挤压工艺参数对模具力学行为的影响[J].锻压技术,2022,47(11):179-186.

Liu G Y, Hao P P, Wan L. Influence of extrusion process parameters on mechanical behavior of die based on HyperXtrude[J]. Forging & Stamping Technology, 2022,47(11):179-186.

Service：

【This site has not yet opened Download Service】【Add Favorite】