铝型材挤压过程数值模拟及模具优化设计
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摘要
针对目前生产中存在的模具设计凭借经验和反复生产来设计的问题，本文以方形管铝型材为研究对象，通过三维立体建模软件Solidworks构建了挤压方形管铝型材的平面分流组合模。然后通过模拟软件Deform-3D对挤压过程进行了模拟。最终通过模拟获得的数据，对平面分流组合模进行了优化设计。
在利用三维建模软件建模时，主要介绍了平面分流组合模的设计步骤，并详细介绍了平面分流组合模结构参数对挤压过程的影响。
利用Gleeble—1500热力模拟试验机对6063铝合金(400℃～520℃)的不同应变率和应变了进行了热力模拟试验，获得了6063铝合金的真实应力—应变曲线和方程。
用正交试验法分别确定了内斜度、外斜度和焊合腔深度的最佳方案，并通过模拟软件Deform-3D对正交试验方案进行了模拟，对挤压筒等效应力和焊合腔静水压应力进行了观察分析。最后在上述研究的基础上，提出了平面分流组合模优化设计的措施。
Alloy profile of square is analyzed. The porthole die by using SolidWorks are designed and the protrusion by using Deform-3D are simulated. The data of simulation are obtained, at last the optimization design of the porthole die are gained.
Design steps of the porthole die and effect of the structure parameters to the protrusion process are introduced.
By using Gleeble-1500 thermomechanical simulator, compressed tests of aluminum alloy are made in certain temperature, at certain strain rate and strain, the true stress-strain curve and equation of 6063 aluminum alloy are gained.
By the method of orthogonal experiment, the optimum technical parameters are selected, which are inside slope, outside slope and depth of the weld-chamber. By using Deform-3D, the effect stress of the porthole and mean stress of the weld-chamber are analyzed. Based on the above, the measures to improve the design of porthole die are proposed.
在利用三维建模软件建模时，主要介绍了平面分流组合模的设计步骤，并详细介绍了平面分流组合模结构参数对挤压过程的影响。
利用Gleeble—1500热力模拟试验机对6063铝合金(400℃～520℃)的不同应变率和应变了进行了热力模拟试验，获得了6063铝合金的真实应力—应变曲线和方程。
用正交试验法分别确定了内斜度、外斜度和焊合腔深度的最佳方案，并通过模拟软件Deform-3D对正交试验方案进行了模拟，对挤压筒等效应力和焊合腔静水压应力进行了观察分析。最后在上述研究的基础上，提出了平面分流组合模优化设计的措施。
Alloy profile of square is analyzed. The porthole die by using SolidWorks are designed and the protrusion by using Deform-3D are simulated. The data of simulation are obtained, at last the optimization design of the porthole die are gained.
Design steps of the porthole die and effect of the structure parameters to the protrusion process are introduced.
By using Gleeble-1500 thermomechanical simulator, compressed tests of aluminum alloy are made in certain temperature, at certain strain rate and strain, the true stress-strain curve and equation of 6063 aluminum alloy are gained.
By the method of orthogonal experiment, the optimum technical parameters are selected, which are inside slope, outside slope and depth of the weld-chamber. By using Deform-3D, the effect stress of the porthole and mean stress of the weld-chamber are analyzed. Based on the above, the measures to improve the design of porthole die are proposed.
引文
[1] 刘静安．铝型材挤压模具设计、制造、使用及维修．1999
[2] 赵云路，唐志云，铝塑型材挤压成形技术．2000
[3] 闫洪，包忠诩，柳和生，王美艳．基于数值模拟的铝型材挤压变形规律的研究(Ⅰ)．锻压机械．2000，5：29～30
[4] 闫洪，包忠诩，柳和生，王美艳．基于数值模拟的铝型材挤压变形规律的研究(Ⅱ)．锻压机械．2000，6：31～32
[5] 闫洪，夏巨谌，包忠诩，柳和生．刘家玉．型材挤压模工作带设计计算的数字建模．塑性工程学报．2002，9(1)：70～73
[6] 马思群，孙彦彬，李荭．金属挤压成形的数值模拟技术研究．大连铁道学院学报．2002，23(2)：8～11
[7] 刘汉武，张志萍，王秀海，顾迎新，崔建忠．基于BP遗传算法的铝型材挤压模具优化设计．哈工业大学学报．2000，32(4)：86～88
[8] 帅词俊，倪正顺，尚刚．铝型材挤压分流组合模有限元优化设计．现代机械．2002，3：37～38
[9] 周飞，彭颖红，阮雪榆．铝型材挤压过程有限元数值模拟．中国有色金属学报，1998，8(4)：637～642
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[11] 蔡微，柳瑞清．高温挤压变形的模拟实验研究
[12] 叶治平．铝型材挤压模的分流结构与强度校核．轻合金加工技术，1994，22(1)：23～27
[13] 俞子骁．平面分流焊合成形力的工程简易算法．轻合金加工技术，2000，28(9)：27～29
[14] 于沪平，彭颖红，阮雪榆．平面分流模成形过程的数值模拟．锻压
技术，1999，24(5)
[15]于冬镇．多孔空心铝型材挤压模的优化设计．轻合金加工技术，1996，24(12)：23～25
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[17]解英艳，宋力．铝型材挤压模具工作带长度的合理选择与计算．25～27．
[18]田柱平，郝南海．铝型材挤压模工作带长度的设计方法．山西机械，1999，1：4～5
[19]谢配良，盛伟，游庆．金属塑性成形过程的金属机模拟．锻压机械，1997(4)：45～48
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[21]倪正顺，帅词俊，钟掘．铝型材挤压模具设计的实现造型技术及其实现．模具工业，2002，5：5～7
[22]闫洪，包忠诩，罗忠民，柳和生．型材挤压理论研究．机械工程学报，2000，36(7)：27～30
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[24]宋力．空心铝型材挤压时金属流动的分析．轻合金加工技术．1998，26(2)：28～33
[25]闫洪，包忠诩，柳和生．型材挤压过程三维弹塑性有限元模拟．轻合金加工技术，2000，28(11)：30～33
[26]闫洪，包忠诩，江雄心．型材挤压成形技术的研究[J]．锻压机械，1999，34(6)：50～52
[27]于沪平，彭颖红，阮雪榆．平面分流焊合模成形过程的数值模拟．锻压技术，2000，24(6)
[28]陈文亮，黄诩，翟建军．铝型材挤压模CAD／CAM系统的研究．南
京航空航天大学学报．1995，27(4)：533～538
[29]刘静安．轻合金挤压工具与模具：(上册)．北京：冶金工业出版社，1990
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[31]张新宇，王延辉，高飞，贺旭东．6063铝合金连续挤压工艺研究．
[32]罗亚军，何丹农，张永清，赵军．人工神经网络在塑性成形领域中的应用研究．锻压技术，2001，5：46～49
[33]周杰，尹红灵，朱革，王梦寒，孙新岭．塑性有限元法中的局部节点重定位技术．锻压技术，2001，3：6～8
[34]单德彬，吕炎，王真．金属体积成形过程三维刚塑性有限元模拟技术的研究．塑性工程学报，1997，4(3)：98～102
[35]郑弃非，石力开，谢水生．空心铝型材挤压时金属流动的计算机辅助(CAD)分析．轻合金加工技术，1997，25(2)：22～27
[36]郝南海，张建中．应用有限元法校核铝型材挤压模具工作带设计．太原重型机械学院学报，1996，17(4)：310～312
[37]刘汉武，丁桦，崔建忠．铝型材挤压分流组合模有限元分析与计算．模具工业，1999，4：9～11
[38]胡忠．塑性有限元模拟技术的最新进展．塑性工程学报，1994，1(3)：3～13
[39]J.Lof. Elasto-viscoplastic FEM simulations of the aluminum flow in the bearing area for extrusion of thin-walled sections. Journal of Materials Processing Technology,2001,114:174～183
[40]D.Y.Yang, K. Park, .S.Kang. Integrated finite element simulation for the hot extrusion of complicated Al alloy profiles. Journal of Materials Processing Technology,2001,111:25～30
[41] K.Pandrinath,A.C.Narayana. Computer program for the determination of grain-size statistics and sediment transprot direction. Computer&Geosciences,1993,19(3) :735-743
[42] U.Stahlberg, J.Hou. A UBET-Simulation Meant for Basic Understanding of the Extrusion of Aluminum Profiles.Jourmal of Engineering for Industry,1995,117:485-493
[43] A.S.Wifi, M.N.Shatla, A..Abdel-Hamid. An optimum-curved die profile for the hot forward rod extrusion process. Journal of Materials Processing Technology,1998,73:97-107
[44] T.Nguyen-Thien, Tran-Cong, N.Phan-Thien. An improved boundary element method for analysis of profile polymer extrusion. Engineering Analysis with Boundary Elements,1997,20:81-89
[45] P.UUREZ, P.A.TANGUY. Numerical Simulation of Profile Extrusion Dies Without Flow Separation. Polymer engineering and science,1993,33(15) :971-979
[46] D.Y.Yang, Y.S.Kang. Analysis and Design of Industrial Hot Extrusion Process through Square Dies for Manufacturing Complicated A1 Alloy Profiles. Annals of the CIRP,1996, 45 (1) : 239-243
[47] M.S.Jou, S.M.Hwang, optimal process design in steady-state metal forming by fimit element method-Ⅱ .application to die profile design in extrusion. Int.J.Mach.Tools Manufact.,1993,33(1) :63-70
[48] P.HUREZ, P.A.TANGUY. A New Design Procedure for Profile Extrusion Dies. Polymer engineering and science,1996,36(5) :626-635
[49] MICHAELC.GABRIELE. Profile extrusion evolves from an art to a science. Modern PIastics,1996:58-62
[50] Frank Vollertsen, Axel Sprenger,Jurgen Kraus, Horst Arnet.
Extrusion, channel,and profile bending: a review. Journal of Materials Processing Technology,1999,87:1-27
[51] Wing Kam LIU, Ted BELYTSCHKO , Herman CHANG. An arbitrary lagrangian-eulerian Finite element method for path-dependent materials. Computer methods in applid mechanics and engineering,1986,58:227-245
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[2] 赵云路，唐志云，铝塑型材挤压成形技术．2000
[3] 闫洪，包忠诩，柳和生，王美艳．基于数值模拟的铝型材挤压变形规律的研究(Ⅰ)．锻压机械．2000，5：29～30
[4] 闫洪，包忠诩，柳和生，王美艳．基于数值模拟的铝型材挤压变形规律的研究(Ⅱ)．锻压机械．2000，6：31～32
[5] 闫洪，夏巨谌，包忠诩，柳和生．刘家玉．型材挤压模工作带设计计算的数字建模．塑性工程学报．2002，9(1)：70～73
[6] 马思群，孙彦彬，李荭．金属挤压成形的数值模拟技术研究．大连铁道学院学报．2002，23(2)：8～11
[7] 刘汉武，张志萍，王秀海，顾迎新，崔建忠．基于BP遗传算法的铝型材挤压模具优化设计．哈工业大学学报．2000，32(4)：86～88
[8] 帅词俊，倪正顺，尚刚．铝型材挤压分流组合模有限元优化设计．现代机械．2002，3：37～38
[9] 周飞，彭颖红，阮雪榆．铝型材挤压过程有限元数值模拟．中国有色金属学报，1998，8(4)：637～642
[10] 柳瑞清．模拟法设计制造铝型材挤压模具研究．锻压技术．1993，18(4)：50～52
[11] 蔡微，柳瑞清．高温挤压变形的模拟实验研究
[12] 叶治平．铝型材挤压模的分流结构与强度校核．轻合金加工技术，1994，22(1)：23～27
[13] 俞子骁．平面分流焊合成形力的工程简易算法．轻合金加工技术，2000，28(9)：27～29
[14] 于沪平，彭颖红，阮雪榆．平面分流模成形过程的数值模拟．锻压
技术，1999，24(5)
[15]于冬镇．多孔空心铝型材挤压模的优化设计．轻合金加工技术，1996，24(12)：23～25
[16]刘占功．铝及铝合金挤压模具修正．铝加工技术，1987，3
[17]解英艳，宋力．铝型材挤压模具工作带长度的合理选择与计算．25～27．
[18]田柱平，郝南海．铝型材挤压模工作带长度的设计方法．山西机械，1999，1：4～5
[19]谢配良，盛伟，游庆．金属塑性成形过程的金属机模拟．锻压机械，1997(4)：45～48
[20]闫洪，包忠润，柳和生．铝型材挤压模CAD／CAE／CAN研究进展．轻合金加工技术，1999，27(10)：1～4
[21]倪正顺，帅词俊，钟掘．铝型材挤压模具设计的实现造型技术及其实现．模具工业，2002，5：5～7
[22]闫洪，包忠诩，罗忠民，柳和生．型材挤压理论研究．机械工程学报，2000，36(7)：27～30
[23]吴诗淳．挤压理论．北京：国防工业出版社，1994
[24]宋力．空心铝型材挤压时金属流动的分析．轻合金加工技术．1998，26(2)：28～33
[25]闫洪，包忠诩，柳和生．型材挤压过程三维弹塑性有限元模拟．轻合金加工技术，2000，28(11)：30～33
[26]闫洪，包忠诩，江雄心．型材挤压成形技术的研究[J]．锻压机械，1999，34(6)：50～52
[27]于沪平，彭颖红，阮雪榆．平面分流焊合模成形过程的数值模拟．锻压技术，2000，24(6)
[28]陈文亮，黄诩，翟建军．铝型材挤压模CAD／CAM系统的研究．南
京航空航天大学学报．1995，27(4)：533～538
[29]刘静安．轻合金挤压工具与模具：(上册)．北京：冶金工业出版社，1990
[30]刘静安．轻合金挤压工具与模具：(下册)．北京：冶金工业出版社，1990
[31]张新宇，王延辉，高飞，贺旭东．6063铝合金连续挤压工艺研究．
[32]罗亚军，何丹农，张永清，赵军．人工神经网络在塑性成形领域中的应用研究．锻压技术，2001，5：46～49
[33]周杰，尹红灵，朱革，王梦寒，孙新岭．塑性有限元法中的局部节点重定位技术．锻压技术，2001，3：6～8
[34]单德彬，吕炎，王真．金属体积成形过程三维刚塑性有限元模拟技术的研究．塑性工程学报，1997，4(3)：98～102
[35]郑弃非，石力开，谢水生．空心铝型材挤压时金属流动的计算机辅助(CAD)分析．轻合金加工技术，1997，25(2)：22～27
[36]郝南海，张建中．应用有限元法校核铝型材挤压模具工作带设计．太原重型机械学院学报，1996，17(4)：310～312
[37]刘汉武，丁桦，崔建忠．铝型材挤压分流组合模有限元分析与计算．模具工业，1999，4：9～11
[38]胡忠．塑性有限元模拟技术的最新进展．塑性工程学报，1994，1(3)：3～13
[39]J.Lof. Elasto-viscoplastic FEM simulations of the aluminum flow in the bearing area for extrusion of thin-walled sections. Journal of Materials Processing Technology,2001,114:174～183
[40]D.Y.Yang, K. Park, .S.Kang. Integrated finite element simulation for the hot extrusion of complicated Al alloy profiles. Journal of Materials Processing Technology,2001,111:25～30
[41] K.Pandrinath,A.C.Narayana. Computer program for the determination of grain-size statistics and sediment transprot direction. Computer&Geosciences,1993,19(3) :735-743
[42] U.Stahlberg, J.Hou. A UBET-Simulation Meant for Basic Understanding of the Extrusion of Aluminum Profiles.Jourmal of Engineering for Industry,1995,117:485-493
[43] A.S.Wifi, M.N.Shatla, A..Abdel-Hamid. An optimum-curved die profile for the hot forward rod extrusion process. Journal of Materials Processing Technology,1998,73:97-107
[44] T.Nguyen-Thien, Tran-Cong, N.Phan-Thien. An improved boundary element method for analysis of profile polymer extrusion. Engineering Analysis with Boundary Elements,1997,20:81-89
[45] P.UUREZ, P.A.TANGUY. Numerical Simulation of Profile Extrusion Dies Without Flow Separation. Polymer engineering and science,1993,33(15) :971-979
[46] D.Y.Yang, Y.S.Kang. Analysis and Design of Industrial Hot Extrusion Process through Square Dies for Manufacturing Complicated A1 Alloy Profiles. Annals of the CIRP,1996, 45 (1) : 239-243
[47] M.S.Jou, S.M.Hwang, optimal process design in steady-state metal forming by fimit element method-Ⅱ .application to die profile design in extrusion. Int.J.Mach.Tools Manufact.,1993,33(1) :63-70
[48] P.HUREZ, P.A.TANGUY. A New Design Procedure for Profile Extrusion Dies. Polymer engineering and science,1996,36(5) :626-635
[49] MICHAELC.GABRIELE. Profile extrusion evolves from an art to a science. Modern PIastics,1996:58-62
[50] Frank Vollertsen, Axel Sprenger,Jurgen Kraus, Horst Arnet.
Extrusion, channel,and profile bending: a review. Journal of Materials Processing Technology,1999,87:1-27
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