Research On Extrusion Die Design And Numerical Simulation For Heat-radiation Aluminum Profile Of High-power LED Lamp

LED lamp with low consumption, high brightness, long life and othercharacteristics, in today’s advocates energy conservation and emissionsreduction is increasingly becoming the focus of attention. With thedevelopment of green lighting project, the application of LED lamps arebecoming more and more widely used. In order t o reduce the light failurephenomenon generated by the heat dissipation problem, the cooling aluminumprofiles are increasing varieties. By far the most common type of it is fin, andextrusion is one of the main modes of production.Extrusion forming process play a key role in the process of aluminumproduction, its technological level decides the quality of profile and the life ofextrusion mould. But in actual production, the mould design is still at thestage of experience analogy. And in order to ensure the success rate, themoulds need to be repeatedly tested and repaired. It is not only lowproductivity, high cost and long cycle, but also difficult to ensure the qualityof product. At the same time, the extrusion is so complex and the traditionalmethod to explore the mechanism of extrusion deformation of materials inmould cavity is difficult.The metal in the deformation process such as speed, temperature, stress andstrain, etc. can be obtained through the numerical simulation method. It canhelp us understand the situation of deformation and the distribution of themechanism of deformation of metal and predict the possible defects such astwisting, bending of profile. To a certain extent, reducing the mold repair times can not only improve the product quality but also reduce the cost. Themain contents and results of this paper are as follows:(1) The paper introduces the basic principles and control equations of ALEmethod. The steady-state numerical simulation was carried out on a rodextrusion process by means of HyperXtrude software. The temperature andvelocity distribution of the section ha ve been obtained. Then compared withthe experiment, we can find out that the deformation trend was consistent. Inconclusion, this method can successfully p redict the potential defects that mayoccur during the extrusion process. So numerical simulation can providetheory basis for the formulation of the process parameters and die design.(2) Design the extrusion die of heat-radiation aluminum profile ofhigh-power LED Lamp according to the relevant theories and principles ofextrusion die design.Numerical simulation model of cooling aluminumprofile of High-power LED Lamp extrusion process have been established.And the information of temperature, velocity, stress state and strain statedistribution of the aluminum profile have been gained.(3) Systemly studied the extrusion temperature, extrusion speed andextrusion ratio on the extrusion process. The process parameters on theinfluence of temperature, extrusion and deformation situation have been got.(4) The extrusion process parameters as the target to reduce the extrusionpressure have been optimized based on the TAGUCHI method. Studies showthat the extrusion speed had the greatest influence of extrusio n, billetdiameter times, billet preheating temp erature is small, the influence of diepreheating temperature influence is minimal.