Effects of Solid Die Types in Complex and Large-Scale Aluminum Profile Extrusion

Increasing customer requirements for quality and productivity in extruding aluminum products has led to the development of different types of extrusion dies. In this study, three different types of dies, including traditional flat die, pocket die and spread die were designed to extrude complex and large-scale solid profiles. The design parameters for these dies were used from actual extrusion experience. The results obtained from steady-state simulation such as velocity, temperature, extrusion force, and die deformation were used to assess the advantages and disadvantages of the dies. Transient simulations were performed to analyze the evolution of transverse weld in the pocket and spread dies. The effects of ram speeds on the related extrusion parameters were also investigated. The research results provide useful guides for designers and engineers in selecting these types of extrusion dies.

FVM Simulation of Porthole Die Extrusion Process for a Large Caliber Aluminum Tube Profile

Aiming at the aluminum profile extrusion process of a large caliber aluminum tube with porthole die, this paper established the simulation models by using finite element method and finite volume method, respectively. The extrusion process was simulated by using the above two models. The advantages and disadvantages and the applicability of the two simulation methods in simulating large aluminum profile extrusion processes were compared. It is concluded that finite volume method is more suitable than finite element method for simulating aluminum profile extrusion processes with a severe deformation. In addition, the distributions of stress and strain and the material flow patterns in the large caliber aluminum tube extrusion process with porthole die were given in detail. The results can provide useful theoretical guidelines for the process and die design as well as process parameter optimal selection for large aluminum profile extrusion processes with porthole die.

Analysis on the Optimal Process of Aluminum Profile Extrusion with Two-Hole Dies

In this paper, using orthogonal design method, considering the extrusion temperature, extrusion speed, extrusion billet, die structure, which will affect the uniformity of the metal flow[1]. Using the outlet velocity average standard deviation, the average pressure and the mean maximum equivalent stress as the criterion, select the optimal process scheme of two-hole dies aluminum profile extrusion. And the optimal scheme is validated by simulation and, the results show that the extrusion velocity is uniform, no forming defects, it can stably forming. At the same time, the experiment provides theoretical guidance for real extrusion production with multi-hole dies.

Comparison of the Thermo-Mechanical Conditions in an Industrial Sized Hot Aluminium Extrusion Process in Relation to those in Corresponding Small Sized Laboratory Processes

It is common to use scaled down laboratory extrusion processes in order to physicalmodel the industrial big-sized aluminum profile extrusion process. In industrial extrusion use ofbillets with a diameter size of ~210 mm, or above, is common. In the scaled-down laboratoryprocesses half this size is often used, and in mini-extrusion also 1/7th of this size. An investigationhas been undertaken in order to study what are the thermo-mechanical conditions in extrusionprocesses of such different sizes of processes, and to what extent a small-sized process is able tophysical model accurately the conditions in an industrial large sized process.

Optimization of a Porthole Die for an Aluminum Profile Extrusion Based on Orthogonal Test Method

In the present work, an attempt was made to solve the problem of distortions during the trial extrusion of an automobile shock absorption by means of orthogonal test method and HyperXtrude software based on ALE (Arbitrary Lagrangian Eulerian) method. According to orthogonal test arrangement, nine times simulations were carried out to study the effects of four significant parameters on distortions. Analysis shows that the influence of bearing length on the outlet velocity uniformity is the largest among the four selected factors. The material flow will be held up obviously with bearing length increasing because of the friction enlargement. But once the bearing length is beyond a critical value, its influence on flow resistance will decrease suddenly. The analysis also confirms that the baffle-block height and ram speed also have considerable influence on outlet velocity uniformity. And the impact of welding-chamber height on outlet velocity uniformity is slight and could be ignored. Finally, the die structure was optimized on the basis of the optimal combination of parameters obtained though the results and analysis of the simulation test. Extrudate with high quality were obtained.

Oval Aluminum Tube Extrusion Process Simulation with Two-Hole Dies

In this paper, the process of two-hole dies extrusion oval aluminium tube simulation analysis is carried out by the Deform-3D software .The simulation includes blank shunt, welding and extrusion deformation process. Temperature and stress distributions of the extrusion deformation is obtained through the simulation. It reveals the key factors of the two-hole dies extrusion forming stably, that is when the metal extrusion die holes, two holes each particle extrusion speed differences within a reasonable range, the extruded profile can stably forming. Putting forward the key factors theory of two-hole dies of aluminum profile extrusion forming stably provides a theoretical guidance for the production of aluminum production with multi-hole dies.