The Numerical Simulation For Continuous Extrusion Cladding (CONCLAD) Process

As the development of electrical wire and cable technology, the higher demand is required in the aspects of high electric conductivity, soling, corrosion-resisting, high strength etc. the traditional single material hardly meets the need of these demands. Multi-material cladding wire gathers the advantages of internal elements, and become the high performance material, which can economize the metal.The dissertation is carried out by DEFORM on the basis of the analysis of the theory and FEM for the double-material CONCLAD processing, which has simulated the temperature field, effective stress field, effective strain field, mean stress field, and velocity field under condition of the various parameters, by which the rules that can realize the rapid design for the dies are got. What is more, the conclusions achieved also fit the multi-material CONCLAD processing.The results show that the height of clad forming zone is a key parameter to the design of die and fitting. The increase of the die height will result in the core rupature. The change of the die angle has little influence on the CONCLAD processing, and the mean stress, effective stress and stain are of no changes nearly. The result of increasing the extrusion temperature by changing the dimensions of the die is not in evidence. The extrusion velocity is also an important parameter for the CONCLAD processing. If the only velocity is considered, the increase of the extrusion velocity can lead to the core rupature, and the decrease to the decrease of the product efficiency. Increasing the billet temperature will prevent the core rupature, but the high temperature will decrease the mean stress and affect the quality of the fuse between the surfaces. The high friction coefficient will not only increase the mean stress, but also increase the effective stress. High friction coefficient can lead to the core rupature. Increasing extrusion velocity can bring the increase of billet temperature, which can compensate the problem of core rupture caused by feed velocity increasing. In this case, increasing feed velocity will not result the core rupture. In the view of the three dimensions FEA, the stress and strain centralize the entrance of bearing belt, and the dead zone is formed in the bottom cladding chamber. The result by the simulation agrees with the one of the experiment, such as core rupature, sheath and the theory of the neutral point. The influence of the height of the cladding deform zone to CONCLAD, and the influence of the friction coefficient to the CONCLAD accord with the other theory such as the diagram of forming limit in CONCLAD.