Numerical Simulation Research Of Heavy Hollow Section Aluminum Profile Extrusion Process

With the development of aluminum extrusion technology day after day, aluminum alloyprofiles are transforming toward large-integrated, high-precision, thin-flat, statuesque andshape complicated, and the products are having good economic benefit. Traditionalexperience analogy method has been unable to meet the current aluminum extrusionmanufacturing industry needs. Aluminum profile extrusion is an efficient precision plasticforming technology, numerical simulation method is an effective method to introduce intoaluminum extrusion design steps. How to speed up the analysis and modeling, reduce analysistime and increase computational efficiency means great significance for introducing thenumerical simulation.This paper summarizes and analyzes mass production examples, introduces theknowledge and experience about large hollow section aluminum profile extrusion process andmould processing technology. Extrusion process parameters are detailed analyzed andconfirmed, and the main form and reason of extrusion forming defects are discussed. Usingthe HyperXtrude module based on the ALE method, steady state simulation on the extrusionprocess of the hollow aluminum profile is presented. Comparing the simulation withexperiments, the feasibility and accuracy of the analysis are proved.The application of Arbitrary Lagrangian-Eulerian finite element method andrigid-viscoplastic finite element method on extrusion simulation are discussed in detail. Usingthe HyperXtrude module based on the ALE method and Msc.Marc software based on therigid-viscoplastic finite element method, steady state simulation on the extrusion process ofthe hollow aluminum profile is presented. The field distributions of temperature, metal flowvelocity, stress and strain rate are obtained. The equilibrium of velocity at the exit isquantitatively judged by SDV value of flowing particles velocity at the exit. Comparing thetwo methods, the calculation results of ALE method are more accurate, and rigid-viscoplasticfinite element method takes less computing time.Based on the steady state numerical analysis of extrusion process by ALE method,further using elastic-plastic finite element theory, force load and deformation situation of amulti-mandrel extrusion die are analyzed. Feeder plate protection, short bridge and three-levelwelding room structures are introduced to improve die quality and to extend its working life.Metal flow controlling are achieved by adjusting bearing length and middle edge thickness,and finally qualified products are obtained.