Research On The Numerical Simulation Of Hot Extrusion Process For Aluminum Alloy Profiles Based On OpenFOAM

In recent years,with the advantages of light weight,high strength,corrosion resistance and beautiful appearance,aluminum alloy profiles have been widely used in the field of architecture,transportation and equipment manufacturing industry.With the increase of the variety of profiles and the increase of complexity of the profiles,the design difficulty of the extrusion die is gradually increased.The design of the traditional extrusion die mainly depends on the designer's experience,which leads to low production efficiency and can not meet the requirements of production design.However,the rapid development of numerical analysis methods provides a new idea for the design of extrusion die.So far,there are mainly two numerical analysis methods used in the field of metal plastic deformation,which are finite element method(FEM)and finite volume method(FVM).When using the finite volume method to simulate the extrusion process,it is possible to avoid the problem that the material's welding behavior(such as DEFORM software)and the flow of material(such as HyperXtrude software)can not be simulated correctly,which are produced in finite element method.Therefore,the research on steady-state and unsteady-state simulation of hot extrusion process for aluminum alloy profiles are carried out based on finite volume method with the open source computational fluid dynamics(CFD)software OpenFOAM.The main work and conclusion are as follows:(1)The velocity boundary condition,the temperature boundary condition and the constitutive model program are compiled based on the OpenFOAM platform for the numerical simulation of hot extrusion process for aluminum alloy profiles.(2)Based on the steady-state solver simpleFoam source code,the program of a new solver is developed,and the steady-state hot extrusion process of a H-shaped profile,a irregular section profile and a hollow profile are simulated.By comoparing with the numerical simulation results of commercial finite element software HyperXtrude,the developed code of the steady-state simulation of hot extrusion process for aluminum alloy profiles is validated.(3)The program of moving mesh is developed,and the interface tracking algorithm for the interDyMFoam solver is added.Finally,the program of a new solver is developed,and the unsteady-state hot extrusion process of a T-shaped profile,a irregular section profile and a hollow profile are simulated.The developed code of unsteady-state hot extrusion process of the aluminum alloy profiles is verified by comparing the numerical results with commercial finite element software DEFORM.