Mold Design And Multi-step Welding Chambers Numerical Simulation For Complex Aluminum Alloy Hollow Profiles By HyperXtrude

The uniformity of metal flow velocity of aluminum alloy profile extrusion is affected by temperature, extrusion speed, size and shape of the profile and some other extrusion parameters. In the production of complex aluminum alloy hollow profiles, it is not easy to control the metal flow velocity by just modifying the structure and size of the die bearing. Generally, we need to modify the die and test the extrusion repeatedly.In this paper, an extrusion die for a complex aluminum alloy hollow profile (JN165A04) based on the profile structure and principles of extrusion die was designed. And the extrusion process of an aluminum alloy divergent die with multi-step welding chambers and isometric die bearing was simulated and analyzed by using the HyperXtrude software. As the result, the flow speed of metal could be controlled to be more uniform by modifying the height, size and shape of the welding chambers by using of the multi-step welding chambers technology.In the production of the profile extruded by a multi-step welding chambers die, the flow speed of metal is affected by the total height of the welding chambers, the height of each step of welding chambers and the size and shape of the welding chambers. When the total height is the same and the height of each step is equal. The more steps the die has, the more uniform the metal flows. For three-step welding chambers dies with different height distributions of welding chambers, the die with equal height of each step of welding chambers has the most uniform metal flow, then the "forward" die. The "backward" die is the worst. When the shapes of welding chambers of multi-step welding chambers dies are similar, the flow of metal is similar as well. When the number of steps and the height are same, the flow of metal is affected by the size and shape of the welding chambers. When the area of welding chamber is increased, the speed of metal flow is high. Increasing the width of welding chamber in profile where flow speed is slow, or decreasing the width of welding chamber in profile where flow speed is fast, will make the flow of metal more uniformTaking JN165A04profile for an example, actual compression test was applied to multi-step welding chambers die, the result shows that the actual extrusion deformation and deformation simulation are basically the same, mold testing stub bar matches the simulated mold testing stub bar, which indicates that multi-step welding chambers technology can adjust the flow speed of metal, which is highly practical in the extrusion of profiles with complex section.