Research On Thermo-plastic Forming Simulation Of Aluminum Alloy Rudder Base

Aluminum alloy extrusion is a metal forming process.Compared with other traditional aluminum alloy processing processes,it has the advantages of good structure performance,high material utilization and high forming accuracy.However,at present,the development of extrusion dies is mainly based on the experience and knowledge obtained by the die designer through repeated experiments,and the accumulation of such experience and knowledge is expensive,time-consuming and inefficient.Therefore,this paper uses numerical simulation to study aluminum alloy Extrusion process.The research object of this article is the 7075 aluminum alloy steering gear base.This part is produced by hot extrusion process to avoid the problems of long machining cycle and low material utilization caused by machining production.Perform structural and technological analysis of parts,formulate different extrusion process schemes,determine the range of extrusion process parameters,use the 3D modeling software Creo to model the dies and blanks,and import the built model into Deform-3D software,Adjust the positional relationship between the die and the blank and set the process parameters for numerical simulation,and determine the best process plan by analyzing the billet flow,extrusion load,equivalent stress and strain field,and temperature field distribution in the simulation post-processing And extrusion parameters,the main contents are as follows:(1)Three extrusion schemes were designed according to the structural characteristics of the parts,and the simulation results were compared and analyzed.It was found that scheme 1had folding extrusion defects in the middle stage of extrusion,which seriously affected the performance of the parts.Analyze and redesign the plan,so that plan two and plan three cleverly avoid this defect.In the case of good forming,the maximum load of scheme three is lower than scheme two,and the extrusion process of scheme two takes a long time,and the punch needs to be replaced,which affects the extrusion efficiency.(2)The simulation analysis of the forming process of blanks with different fillet radii found that different fillet radii have a greater impact on the forming results.When the fillet radii are small,folding defects will occur during the extrusion process.The larger the corner radius,the better the forming of the extruded part.Through simulation analysis of different process parameters,it was found that the smaller the extrusion speed,the lower the deformation resistance,the smaller the required extrusion force,and the temperature rise effect and stress concentration phenomenon.The less obvious;the extrusion temperature also has a greater impact on the extrusion force and equivalent stress,but has a smaller effect on the temperature rise and temperature difference after extrusion,so the higher temperature is used to squeeze the parts on the premise of ensuring performance;The lower the friction coefficient,the lower the equivalent strain and the required squeezing force,which can achieve better surface quality and reduce the requirements on the equipment.(3)The die stress was analyzed,and the upper and lower dies were less stressed.Subsequently,the die wear was analyzed.It was found that the maximum wear depth of the lower die was much higher than the upper die,and the lower die wear was uneven.The lower die support small module Wear is the worst.The influence of die initial hardness on die wear was studied,and it was found that increasing the die initial hardness can effectively improve the abrasive wear.After designing the die structure,the trial-produced parts were extruded with full shape and shape in accordance with the expected results.