Research On Numerical Simulation Of Aluminum Profile Extrusion Process And Structure Parameters Optimization Of Extrusion Die

With the rapid development of china’s economy and the promotionof people’s environmental protection concept, higher requirements are putforward to the depletion of resources and energy. Therefore, how toeffectively improve the production efficiency of aluminum profile andcost reductions has become an important research topic in the aluminumindustry. Traditional extrusion die structure designs and technologicalparameters sets depend mostly on the experience and the analogicalmethod, which needs repeat testing and modifying the die structure toproduce the qualified products, it increased production cost and restrictedthe development of the aluminum extrusion industry in our country.Along with the progress of the CAD/CAM/CAE technology, thedevelopment of plastic forming theory and finite element theory,combining the traditional aluminum extrusion craft with the numericalsimulation technology to study the aluminium profile extrusion processand optimize the structure of die have become the development trend ofaluminum industry.This article first introduces the main structure and the designprinciples of die, discusses the basic principle and equation of arbitrarylagrangian-eulerian method, using the finite element numerical simulationsoftware named HyperXtrude which based on the arbitrarylagrangian-eulerian method to simulate the extrusion process in thesteady state, get the metal flow and the distribution situation in the die,and predicate the deformation trend of extrusion profiles, verified thereliability of software with comparing the simulation results with testresults. Second, makes a study of structure optimization of flow guide die,analyzes the influence of different extruding technological parameters onthe extrusion process, to provide theoretical basis for the establishment oftechnological parameters in practical production. Optimizing the structureof plane porthole die based on the simulation results, and discussing thedeformation and stress distribution of the die with change the depth of welding chamber and the width of triage bridge.Basing on the discussion of the die structure impact on the extrusionprocess, at the end of this paper, it shows that the main reason of diecrack is the stress concentration through comparing the simulate resultwith actual situation. Using the plane porthole die which produces thealuminum tube as the research object, the thickness of upper die, widthand intersection angle of the triage bridge, and depth of welding chamberare selected as the design variables, and the maximum equivalent stress ofdie in the extrusion process acts as the optimization objective, using theOrthogonal test table to establish the training sample, establishing thepredicting response model with the GABP neural network, and combinethe Simulated Annealing Genetic Algorithm to search the best value inglobal field. Building the model with the optimized parameters, comparedwith the optimal value in the sample data, the results shows that themaximum equivalent stress of die decreased by15%, it means the servicelife of the die is prolonged, also the exit velocity distribution of profilebecome homogeneous and the deformation of profile decreases, itprovides a new way for the structure parameters optimization of the die.