Research On Metal Flow Regularity Of Extrusion Process For The Large-scale Aluminum Material

For the present,the use of Aluminum alloy profile becomes more and more popular. Extruding method is commonly used in the production,because it can not only save raw material,but also has high productivity.So it is taken into account increasingly.However, die design often depends on the experience and trial-and-error over and over in production. In addition,the pattern of metal flow,stress distribution,strain distribution and stress of die are unclear because the extrusion process is accomplished in a closed chamber.With the development of CAD/CAE in production,Al6061 alloy profile of square tube is analyzed. The porthole die is designed by using CAD software solid works and the process of extrusion is simulated by Rigid-Plastic FEM software Deform-3D.And it is implemented the optimum design.In the actual extrusion process,it is found that for the same area of central vietnam the farther from the center,the speed is greater.The height is greater in the same time.In order to ensure the similar flow rate,the mathematical relation of extrusion rate and the area and position of porthole holes are created in extrusion-drum radius 230mm and 285mm,it is newly.By use of the relational expression,it can be calculated the other parameters if the one is known.Thus,it can be achieved controlling export height and extrusion flow,which provides a theoretical basis for the design of the dies.Firstly,it is introduced design principle of the porthole die and the theory of rigid-plastic.Secondly,the parameters and process of extrusion craft of A16061 alloy are calculated by DEFORM.Subsequently,it is found that the reason of die damage is streaming hole design errors which led to the stress concentration.Base on this reason, calculate the bearing length again,and adjust the size of streaming hole to meet the same speed,as requested by the metal flow rate(of bonding indoor) the same.Avoid the liquid metal bonding transverse indoor mold core mobility without bending,basically resolved the cracking problem caused by the stress concentration.The data are obtained from the Post-Processor of DEFORM-3D as the graph of Load-Stroke,the effective strain and stress distribution of the work piece and the exit velocity of material flow.It must be improve the quality and efficiency of mold design and carry out the high quality,low cost and short period of mold development.