孟佳杰,徐琅,李国钧,等.大型复杂薄壁铝合金空心型材挤压成形工艺[J].精密成形工程,2023,15(4):58-66.
MENG Jia-jie,XU Lang,LI Guo-jun,et al.Extrusion Forming Process of Large and Complex Thin-walled Aluminum Alloy Hollow Profile[J].Journal of Netshape Forming Engineering,2023,15(4):58-66. |
| 大型复杂薄壁铝合金空心型材挤压成形工艺 |
| Extrusion Forming Process of Large and Complex Thin-walled Aluminum Alloy Hollow Profile |
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| DOI：10.3969/j.issn.1674-6457.2023.04.007 |
| 中文关键词: 大型复杂薄壁铝合金空心型材 数值模拟 流速均方差 模具应力 模具结构优化 |
| 英文关键词: large and complex thin-walled aluminum alloy hollow profile numerical simulation speed deviation die stress die structure optimization |
| 基金项目:上海市青年科技启明星项目(21QB1404500);上海航天科技创新基金(SAST2020–044) |
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| 中文摘要: |
| 目的 解决大型复杂薄壁铝合金空心型材挤压过程中材料流速均匀性控制难，以及模具局部应力集中导致模具寿命低、挤压型材尺寸稳定性差的问题。方法 采用有限元模拟方法对此类典型型材挤压过程进行仿真分析，根据仿真结果中型材出口材料流速分布情况，通过调控不同部位材料流入量及材料流动阻力，并以型材出口流速差和流速均方差(SDV)作为衡量挤压过程中材料流速均匀性的指标，逐步迭代优化模具结构以提高材料流动均匀性;根据仿真结果中挤压模具应力分布情况，以模具最高应力作为衡量模具强度的指标，逐步迭代优化模具结构以减小模具应力。结果 通过迭代仿真依次优化模具工作带长度、分流孔尺寸、阻流块高度等参数，最终型材出口流速差由25.07 mm/s降至2.72 mm/s，流速均方差由9.84 mm/s降至0.72 mm/s;通过迭代仿真优化焊合角度，最终模具最高应力由945 MPa降至863 MPa。采用基于有限元仿真优化结构的挤压模具成功制备了合格的铝合金型材样件，挤压试验结果与数值模拟结果吻合。结论 通过优化模具工作带长度、分流孔尺寸及阻流块高度，调控不同部位材料流入量及材料流动阻力，能够有效解决大型复杂薄壁铝合金空心型材挤压流速均匀性差的问题;通过优化模具焊合角度，能够显著降低模具局部应力集中。 |
| 英文摘要: |
| The work aims to solve the problem that it is difficult to control the material velocity uniformity during the extrusion process of large and complex thin-walled aluminum alloy hollow profiles, and the local stress concentration of the die leads to short die life and poor dimensional stability of the extruded profile. The extrusion process of this profile was simulated and analyzed by finite element simulation. According to the material velocity distribution of the extruded profile in the simulation results, by adjusting the material inflow amount and material flow resistance in different parts, and the velocity difference of the extruded profile and the speed deviation (SDV) were used as indexes to measure the velocity uniformity of the material, and then the die structure was optimized gradually to improve the material flow uniformity. According to the stress distribution of the extrusion die in the simulation results, the maximum stress of the die was used as an index to measure the strength of the die, and then the die structure was optimized gradually to reduce the stress of the die. By optimizing parameters such as length of working belt, size of porthole and height of blocking block, the velocity difference of the extruded profile was reduced from 25.07 mm/s to 2.72 mm/s, the SDV was reduced from 9.84 mm/s to 0.72 mm/s. By optimizing the welding angle by simulation, the maximum stress of the die was reduced from 945 MPa to 863 MPa. The aluminum alloy profiles with qualified dimensional accuracy and mechanical properties were successfully prepared with the extrusion die with optimized structure, and the extrusion experimental results were in good agreement with the numerical simulation results. By optimizing the length of working belt, size of porthole and height of blocking block, and adjusting the material inflow amount and material flow resistance in different parts, the non-uniform material flow velocity of large and complex thin-walled aluminum alloy hollow profiles can be effectively solved. By optimizing the welding angle of the die, the local stress concentration of the die can be significantly reduced. |
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