Extrusion of aluminum profiles refers to the introduction of aluminum alloy high-temperature slabs into special molds. Under the powerful pressure provided by the extruder, at a given speed, the aluminum alloy is extruded from the mold cavity to obtain the desired shape. , dimensions and aluminum alloy extruded profiles with certain mechanical properties. Aluminum extrusion molding process is very complicated, in addition to the extrusion of circular and circular section aluminum profile is a two-dimensional axisymmetric problem, in general, other shapes of aluminum extrusion is a large three-dimensional flow deformation problem. Therefore, the quality of the extrusion die design and its service life become one of the keys to the economic feasibility of the extrusion process. Reasonable design and manufacturing can greatly extend the life of the mold, which is of great significance for improving the production efficiency, reducing the cost and energy consumption. At present, China's profile extrusion die design basically remains in the traditional accumulation of engineering analogy and design experience. In fact, the more complex the profile section, the more pronounced the non-uniformity of the extrusion deformation, resulting in the new design of the mold is difficult to ensure a uniform outflow of the billet, causing the profile due to twisting, waves, bending and cracks Defective and scrapped, the mold is also very easy to damage, must go through repeated trial mode, repair mode can be put into normal use, resulting in waste of funds, manpower, time, resources, etc. [1]. Therefore, with the continuous development of aluminum profile products to large-scale, flattened, thin-walled, highly refined, complicated and multi-purpose, multi-functional, multi-variety, long-life, improving the traditional mold design method has become the current The urgent needs of aluminum industry development.
1 Significance of CAE Study on Aluminum Profile Extrusion Dies
The aluminum profile extrusion die CAE technology is a numerical technique that uses the extrusion product model established in CAD, combines the extrusion process and control parameters, completes the analysis of its forming process, and optimizes the design of the corresponding die.
The specific approach is: Based on the preliminary design of the extrusion die, according to a preliminarily prepared process test plan, the entire extrusion process is simulated using a computer, and physical stress distributions such as stress, strain, temperature, and flow velocity in the extrusion body are obtained and squeezed. Pressure process conditions such as pressure, temperature, and speed are determined at each stage. The influence of mold sections such as the cross-section of the extrusion die and the diverter holes, weld cavities, diversion grooves, etc. on the flow of the formed aluminum is determined. The mold may appear during use. Deformation, collapse, chipping, cracking, wear, "sticking" and fatigue defects and their location; put forward analysis reports and recommend suitable extrusion conditions to the designer, the designer then corrects the die design program based on the CAE analysis results. After several iterations, until the mold design program meets product design requirements and product quality requirements [2]. This is actually the process of transferring the “trial-modification-testing†process at the production site to the computer to partially replace the time-consuming and costly test-work in the mold design and manufacturing process, thereby reducing the material and energy consumption at this stage. Reduce production costs and design high-quality aluminum extrusion dies.
Although CAE technology has obtained some successful applications in the field of aluminum extrusion die design and manufacturing, it is rarely used for mold engineers. This is mainly due to the fact that there is no CAE software developed specifically for aluminum profile extrusion die at home and abroad. Therefore, when the die engineer uses some common or special CAE software (such as ANSYS/LS DY NA, MARC/AutoForge, Deform, etc.) When designing solutions and mold structure analysis, in addition to requiring the user to have a solid extrusion process and extrusion mold design and manufacturing expertise, and familiar with the working conditions of the extrusion mold components in the coupled field environment, he is also required to conduct numerical simulations. The technology and the corresponding finite element analysis method must have a deeper understanding, which is more difficult for engineering technicians working in the production line. This is also an important issue for CAE technology that is not widely used in the extrusion die industry. one of the reasons.
The application of aluminum extrusion die CAE can shorten the design and manufacturing cycle of the die, improve the quality of the die, and enhance the market competitiveness of the enterprise. However, only by solving the above problems can CAE technology be widely used in the extrusion die industry. This is the significance of the aluminum extrusion die CAE technology research.
2 Aluminum extrusion die optimization design status quo
Because it is a very complicated and difficult job to design a structurally reasonable, economical and practical extrusion die, the extrusion workers all over the world have carried out a large number of theories and methods of die design (especially optimization theories and methods). research work.
At the beginning of the development of extrusion technology, mold design was generally based on mechanical design principles using traditional strength theory combined with the designer's practical experience. With the development of elasto-plastic theory and extrusion theory, many new experimental theories and methods, computational theories and methods have begun to be used in the field of extrusion die design and fabrication. For example, engineering calculation method, metal flow coordinate grid method, photoelastic light-plasticity method, dense grid pattern method, slip line method, upper limit element theory, finite element theory, etc. are widely used in the determination of mold strain field and various The strength of the check, and then optimize the structure and process elements. With the development of computer technology, the CAD/CAM technology of extrusion die has been rapidly developed in the recent 20-30 years, and a large part of the technology is focused on the optimization of die design. He Delin et al.[3] used the IDEF0 method to develop a CAD/CAM system that can optimize the planar mode and the flow diversion mode; Wang Mengjun et al.[4] used AUTOCAD1200 as a graphic support environment and VISUALBASIC4.0 as a development tool. The CAD system can effectively perform the calculations of the extrusion die, thus optimizing the design results; Yan Hong et al. [5] introduced the CAE concept into the die design process and pointed out the direction of optimization design; Liu Hanwu et al. [6] ] The concept of intelligent CAD was proposed to provide some ideas for the intelligent design of moulds. In addition, researchers at home and abroad have used theoretical analysis, physical simulation and numerical simulation to analyze and test the deformation process, distribution and change of stress field and temperature field, friction and lubrication of aluminum extrusions. According to its research results, the extrusion die was optimized. For example, Zhao Yunlu and Liu Jingan [7] systematically discussed the optimization design of various extrusion dies. Some domestic researchers have used the finite element method combined with experimental methods to analyze and optimize the optimal profile of the extrusion die and the die structure.
However, due to the thinness of mold technology, China started late, and there is still a certain gap compared with foreign counterparts at the comprehensive level.
3 Development status and trends of aluminum extrusion die CAE at home and abroad
The numerical simulation of the aluminum extrusion process can predict the possible defects in the actual extrusion process, optimize the mold structure design, adjust the extrusion process parameters and targeted technical solutions. Researchers at home and abroad have done a lot of work on this. South Korea's Hyun WooShin et al. [8] performed a finite element analysis on non-axisymmetric extrusion processes in 1993. They used two-dimensional rigid-plastic finite element methods combined with thick plate theory to simplify three-dimensional problems and perform the entire extrusion process. Accurate numerical simulations are also reduced, while also reducing the amount of calculations. For the deformation simulation, Yu Huping [9] used the plastic forming simulation software DE FORM, combined with the rigid viscoplastic finite element method function method to perform two-dimensional simulation of the extrusion deformation process of the planar diverter die, and obtained the aluminum in the extrusion process. The distribution and variation of the alloy's stress, strain, temperature, and flow rate. Liu Hanwu et al.[10] used ANSYS software to perform finite element analysis and calculations on extruded aluminum extrusions with split-flow dies to identify structural defects that were not easily found in the original die design. Zhou Fei et al. [11] used a three-dimensional rigid viscoplastic finite element method to simulate the non-isothermal forming process of a typical aluminum profile. Three different forming stages of extrusion of aluminum profiles were analyzed, and the stress at each stage of forming was given. , Strain and temperature field distribution, and mold loading as a function of forming time throughout the forming process. For the pressure field, Yan Hong et al [12] used ANSYS software as a platform in 2000 to perform three-dimensional finite element simulation and analysis of the wall profile extrusion process, and obtained the displacement field, strain field, and stress field of the profile extrusion process. . It plays an important role in the selection of process parameters and the correction of the die structure size in the actual profile extrusion. For the friction and lubrication analysis of the extrusion process, in 1997, Russia's VadimL.Bereshnoy et al. [13] studied the technology of friction assist in direct and indirect extrusion of hard aluminum alloys. The development and application of this technology have greatly improved the production efficiency and quality. U.S. PradipK.Saha [14] studied thermodynamics and tribology in extrusion of aluminum profiles in 1998. He used thermodynamic numerical simulation to construct three different experimental models, analyzed the friction characteristics of the mold working zone and the flow metal contact surface, and also the temperature generated by the blank temperature and the heat generated in the extrusion process on the die working zone. The effect of the rise was verified by actual measurements. Studies have shown that friction in the extrusion process has a direct effect on the accuracy and surface quality of the profile. The wear process of the mold working belt depends on the thermodynamic properties during the extrusion process. The thermodynamic properties are again severely affected by the extrusion variables.
In terms of secondary development, some domestic research progress is also worthy of attention. Chen Zezhong and Bao Zhongyu[15] established an aluminum extrusion die CAD/CAE/CAM system based on UG and ANSYS through system integration and secondary development, and conducted CAD/CAE/CAM research on the split flow module. Effectively improve the mold design and manufacturing efficiency. Shenzhen University's Li Jibin [16] wrote a program for the design of aluminum extrusion die parameters in C language, guided the design process of aluminum extrusion die in the form of a flow chart, and realized aluminum extrusion die in the form of human-machine dialogue. The optimal design of the parameters. Duan Zhidong of Lanzhou Railway Institute [17] introduced a strong finite element program for ANSYS applications through ANSYS to provide a powerful front-rear processing and solving function platform. It introduced and summarized the secondary development of graphical user interface with ANSYS using UIDL. The general steps and rules provide useful help for the user to build ANSYS functionality and establish his own dedicated program while establishing a corresponding graphical driver interface. Sheng Wei [18] of Jiangsu Qishuyan Locomotive & Rolling Stock Technology Institute used ANSYS software as a platform to carry out the secondary development of metal plastic forming process simulation software, and applied the software to simulate the plastic forming process of forgings to improve the quality and prediction of forgings. The defects in metal forming and the development of reasonable processes provide a theoretical basis.
However, in general, these studies have focused more on theorization, and an extrusion die finite element analysis software that is truly suitable for common design and manufacturing personnel has not been available in China. Some secondary development also has great limitations in terms of specific applications. Therefore, it is imperative that the user-oriented research of the current finite element software be better applied to the design of extrusion dies.
4 Conclusion
Increasing the level of aluminum extrusion die design and manufacturing is the key to improving product quality and enhancing market competitiveness, while aluminum extrusion die CAE technology plays an important role in the optimization of aluminum extrusion die design.
Domestic and foreign counterparts made use of aluminum profile extrusion die CAE to make beneficial attempts to optimize aluminum profile extrusion die (including extrusion and extrusion processes), and achieved a lot of research and application results. This trend is worth noting.
As soon as possible, the latest finite element analysis technology is applied to the entire extrusion die design and manufacturing process, allowing more die engineers to master this optimized design method to improve the market competitiveness of China's aluminum profile extrusion industry and its die manufacturing industry. .
1 Significance of CAE Study on Aluminum Profile Extrusion Dies
The aluminum profile extrusion die CAE technology is a numerical technique that uses the extrusion product model established in CAD, combines the extrusion process and control parameters, completes the analysis of its forming process, and optimizes the design of the corresponding die.
The specific approach is: Based on the preliminary design of the extrusion die, according to a preliminarily prepared process test plan, the entire extrusion process is simulated using a computer, and physical stress distributions such as stress, strain, temperature, and flow velocity in the extrusion body are obtained and squeezed. Pressure process conditions such as pressure, temperature, and speed are determined at each stage. The influence of mold sections such as the cross-section of the extrusion die and the diverter holes, weld cavities, diversion grooves, etc. on the flow of the formed aluminum is determined. The mold may appear during use. Deformation, collapse, chipping, cracking, wear, "sticking" and fatigue defects and their location; put forward analysis reports and recommend suitable extrusion conditions to the designer, the designer then corrects the die design program based on the CAE analysis results. After several iterations, until the mold design program meets product design requirements and product quality requirements [2]. This is actually the process of transferring the “trial-modification-testing†process at the production site to the computer to partially replace the time-consuming and costly test-work in the mold design and manufacturing process, thereby reducing the material and energy consumption at this stage. Reduce production costs and design high-quality aluminum extrusion dies.
Although CAE technology has obtained some successful applications in the field of aluminum extrusion die design and manufacturing, it is rarely used for mold engineers. This is mainly due to the fact that there is no CAE software developed specifically for aluminum profile extrusion die at home and abroad. Therefore, when the die engineer uses some common or special CAE software (such as ANSYS/LS DY NA, MARC/AutoForge, Deform, etc.) When designing solutions and mold structure analysis, in addition to requiring the user to have a solid extrusion process and extrusion mold design and manufacturing expertise, and familiar with the working conditions of the extrusion mold components in the coupled field environment, he is also required to conduct numerical simulations. The technology and the corresponding finite element analysis method must have a deeper understanding, which is more difficult for engineering technicians working in the production line. This is also an important issue for CAE technology that is not widely used in the extrusion die industry. one of the reasons.
The application of aluminum extrusion die CAE can shorten the design and manufacturing cycle of the die, improve the quality of the die, and enhance the market competitiveness of the enterprise. However, only by solving the above problems can CAE technology be widely used in the extrusion die industry. This is the significance of the aluminum extrusion die CAE technology research.
2 Aluminum extrusion die optimization design status quo
Because it is a very complicated and difficult job to design a structurally reasonable, economical and practical extrusion die, the extrusion workers all over the world have carried out a large number of theories and methods of die design (especially optimization theories and methods). research work.
At the beginning of the development of extrusion technology, mold design was generally based on mechanical design principles using traditional strength theory combined with the designer's practical experience. With the development of elasto-plastic theory and extrusion theory, many new experimental theories and methods, computational theories and methods have begun to be used in the field of extrusion die design and fabrication. For example, engineering calculation method, metal flow coordinate grid method, photoelastic light-plasticity method, dense grid pattern method, slip line method, upper limit element theory, finite element theory, etc. are widely used in the determination of mold strain field and various The strength of the check, and then optimize the structure and process elements. With the development of computer technology, the CAD/CAM technology of extrusion die has been rapidly developed in the recent 20-30 years, and a large part of the technology is focused on the optimization of die design. He Delin et al.[3] used the IDEF0 method to develop a CAD/CAM system that can optimize the planar mode and the flow diversion mode; Wang Mengjun et al.[4] used AUTOCAD1200 as a graphic support environment and VISUALBASIC4.0 as a development tool. The CAD system can effectively perform the calculations of the extrusion die, thus optimizing the design results; Yan Hong et al. [5] introduced the CAE concept into the die design process and pointed out the direction of optimization design; Liu Hanwu et al. [6] ] The concept of intelligent CAD was proposed to provide some ideas for the intelligent design of moulds. In addition, researchers at home and abroad have used theoretical analysis, physical simulation and numerical simulation to analyze and test the deformation process, distribution and change of stress field and temperature field, friction and lubrication of aluminum extrusions. According to its research results, the extrusion die was optimized. For example, Zhao Yunlu and Liu Jingan [7] systematically discussed the optimization design of various extrusion dies. Some domestic researchers have used the finite element method combined with experimental methods to analyze and optimize the optimal profile of the extrusion die and the die structure.
However, due to the thinness of mold technology, China started late, and there is still a certain gap compared with foreign counterparts at the comprehensive level.
3 Development status and trends of aluminum extrusion die CAE at home and abroad
The numerical simulation of the aluminum extrusion process can predict the possible defects in the actual extrusion process, optimize the mold structure design, adjust the extrusion process parameters and targeted technical solutions. Researchers at home and abroad have done a lot of work on this. South Korea's Hyun WooShin et al. [8] performed a finite element analysis on non-axisymmetric extrusion processes in 1993. They used two-dimensional rigid-plastic finite element methods combined with thick plate theory to simplify three-dimensional problems and perform the entire extrusion process. Accurate numerical simulations are also reduced, while also reducing the amount of calculations. For the deformation simulation, Yu Huping [9] used the plastic forming simulation software DE FORM, combined with the rigid viscoplastic finite element method function method to perform two-dimensional simulation of the extrusion deformation process of the planar diverter die, and obtained the aluminum in the extrusion process. The distribution and variation of the alloy's stress, strain, temperature, and flow rate. Liu Hanwu et al.[10] used ANSYS software to perform finite element analysis and calculations on extruded aluminum extrusions with split-flow dies to identify structural defects that were not easily found in the original die design. Zhou Fei et al. [11] used a three-dimensional rigid viscoplastic finite element method to simulate the non-isothermal forming process of a typical aluminum profile. Three different forming stages of extrusion of aluminum profiles were analyzed, and the stress at each stage of forming was given. , Strain and temperature field distribution, and mold loading as a function of forming time throughout the forming process. For the pressure field, Yan Hong et al [12] used ANSYS software as a platform in 2000 to perform three-dimensional finite element simulation and analysis of the wall profile extrusion process, and obtained the displacement field, strain field, and stress field of the profile extrusion process. . It plays an important role in the selection of process parameters and the correction of the die structure size in the actual profile extrusion. For the friction and lubrication analysis of the extrusion process, in 1997, Russia's VadimL.Bereshnoy et al. [13] studied the technology of friction assist in direct and indirect extrusion of hard aluminum alloys. The development and application of this technology have greatly improved the production efficiency and quality. U.S. PradipK.Saha [14] studied thermodynamics and tribology in extrusion of aluminum profiles in 1998. He used thermodynamic numerical simulation to construct three different experimental models, analyzed the friction characteristics of the mold working zone and the flow metal contact surface, and also the temperature generated by the blank temperature and the heat generated in the extrusion process on the die working zone. The effect of the rise was verified by actual measurements. Studies have shown that friction in the extrusion process has a direct effect on the accuracy and surface quality of the profile. The wear process of the mold working belt depends on the thermodynamic properties during the extrusion process. The thermodynamic properties are again severely affected by the extrusion variables.
In terms of secondary development, some domestic research progress is also worthy of attention. Chen Zezhong and Bao Zhongyu[15] established an aluminum extrusion die CAD/CAE/CAM system based on UG and ANSYS through system integration and secondary development, and conducted CAD/CAE/CAM research on the split flow module. Effectively improve the mold design and manufacturing efficiency. Shenzhen University's Li Jibin [16] wrote a program for the design of aluminum extrusion die parameters in C language, guided the design process of aluminum extrusion die in the form of a flow chart, and realized aluminum extrusion die in the form of human-machine dialogue. The optimal design of the parameters. Duan Zhidong of Lanzhou Railway Institute [17] introduced a strong finite element program for ANSYS applications through ANSYS to provide a powerful front-rear processing and solving function platform. It introduced and summarized the secondary development of graphical user interface with ANSYS using UIDL. The general steps and rules provide useful help for the user to build ANSYS functionality and establish his own dedicated program while establishing a corresponding graphical driver interface. Sheng Wei [18] of Jiangsu Qishuyan Locomotive & Rolling Stock Technology Institute used ANSYS software as a platform to carry out the secondary development of metal plastic forming process simulation software, and applied the software to simulate the plastic forming process of forgings to improve the quality and prediction of forgings. The defects in metal forming and the development of reasonable processes provide a theoretical basis.
However, in general, these studies have focused more on theorization, and an extrusion die finite element analysis software that is truly suitable for common design and manufacturing personnel has not been available in China. Some secondary development also has great limitations in terms of specific applications. Therefore, it is imperative that the user-oriented research of the current finite element software be better applied to the design of extrusion dies.
4 Conclusion
Increasing the level of aluminum extrusion die design and manufacturing is the key to improving product quality and enhancing market competitiveness, while aluminum extrusion die CAE technology plays an important role in the optimization of aluminum extrusion die design.
Domestic and foreign counterparts made use of aluminum profile extrusion die CAE to make beneficial attempts to optimize aluminum profile extrusion die (including extrusion and extrusion processes), and achieved a lot of research and application results. This trend is worth noting.
As soon as possible, the latest finite element analysis technology is applied to the entire extrusion die design and manufacturing process, allowing more die engineers to master this optimized design method to improve the market competitiveness of China's aluminum profile extrusion industry and its die manufacturing industry. .
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