铝合金挤压模具型腔优化设计
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摘要
对于铝合金挤压成形而言,凹模型腔轮廓设计是挤压工艺设计中一个重要方面。不适当的凹模型腔轮廓设计会导致过多的材料内部剪切,模口附近金属流动方向急剧变化以及材料挤出速度不均匀等现象的发生。因此,为了控制金属流动,保证模具的应力、应变分布均匀,减小挤压力,需要对凹模型腔轮廓设计进行研究分析。
     本文运用上限法建立铝合金棒材挤压成形的流动模型,推导了坯料在五种不同曲线型腔模具中变形时的动可容速度场、应变速率场及上限功率的表达式。同时,以挤压力最小为优化目标,对成形过程进行优化,获得最低能耗下的型腔曲线长度。为验证上限解的可靠性,对最佳型腔曲线长度下棒材成形过程进行二维有限元数值模拟,得到了挤压力与型腔曲线表面接触应力的分布曲线,数值解与理论解相吻合。
     引入流函数法和保角映射方法,完成了凹模型腔曲面的数学描述,并建立了铝合金壁板扁挤压筒挤压模型。在此基础上,综合考虑型线长度、定径带长度、摩擦因子、挤压速度和型腔形状这五个因素,通过三维有限元模拟,获得了各种不同因素组合下的挤压力以及凹模在该挤压过程中所受到的最大等效应力等信息。从而得出最优的挤压工艺参数与模具设计参数的组合,实现了对铝合金壁板挤压的优化设计。
     本文的研究成果对于完善铝合金挤压模具设计理论具有一定的指导意义。
During the aluminum alloy forming process, die cavity surface design is very important. If the die cavity surface shape is improper, the shearing force will be increased, the direction of metal flow near the die outlet will change rapidly, and the metal flow velocity will not be uniform. In order to avoid these problems and reduce the die pressure, the design of a suitable die cavity surface seems to be necessary.
     An extrusion flow model of aluminum alloy cylinder is built by the upper-bound method, the kinematically admissible velocity field, the strain rate field and the deformation power are deduced with five different die containers. In addition, aiming at reducing the extrusion power, the length of the die containers is optimized. FEM is used to simulate the extrusion process with the best die container length, and then the distribution of extrusion power and die contact stress are obtained. It can be seen that the theoretical results are in good accordance with the simulation results. The results show, with the best die container length and the same area reduction ratio, the third-order polynomial die and the cosine die are the best amongst the profiles considered.
     The mathematic function of die cavity surface is established, and the model for aluminum alloy flat-plate extrusion is constructed. Based on this, the extrusion power and maximum equivalent stress are obtained by using FEM. During this process, some related factors are considered, including die cavity surface length, die calibrating strap length, friction factor, extrusion speed and die cavity surface shape. As a result, the optimal design for aluminum alloy flat extrusion is achieved, and from which the optimum parameters of extrusion process and die design are got.
     The research results have great signification in improving the extruding die design theory for aluminum alloy.
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