铝型材挤压过程数值模拟及模具参数优化
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摘要
目前,铝合金型材在日常生活及生产领域应用越来越广泛,用挤压的方法生产铝型材,既节约金属又具有很高的生产效率,因此该方法在生产和研究领域都日益受到重视。在铝型材挤压工艺生产中,经常凭借经验和反复试模修模来进行模具设计,不可避免的造成人力与物力的耗费。随着CAD/CAE技术在实际生产中的广泛应用,本文以平面分流组合模挤压Al6063多腔壁板型材为研究对象,通过三维造型软件Pro/Engineer创建了多腔壁板铝型材平面分流组合模型,利用刚塑性模拟软件Deform-3D对型材挤压过程进行了模拟,从而实现了对模具参数的优化。
本文首先论述了平面分流组合模具的设计原则,简单介绍了刚塑性有限元理论和金属流速的判据公式,从工艺因素和几何因素方面系统介绍了影响挤压金属流动的因素。为了定量的反映几何因素在型材挤压时对金属流速的影响,利用数值模拟的方法得出了工作带长度与金属流速的关系以及局部挤压比、模孔位置、模孔的挤压工作带面积和工作带长度之间的关系。最后通过对图形文件的输入、网格细分技术,步长增量的选取以及自接触等模拟关键问题的探讨,成功地对多腔壁板铝型材挤压过程进行了模拟,得到了一组比较理想的模具参数。
本文创新性地对平面分流组合模的结构进行了一些改进,提出了分流宽展模结构和流线模结构的设计思想,为壁板类铝型材挤压模具优化设计提供了全新的思路。通过模拟分析的结果可以看到,在分流孔中进行宽展不仅降低了因为单独使用宽展模具而增加的挤压力,而且可以挤压比圆挤压筒直径更宽的壁板型材。而把流线模型应用在分流模具上可以有效的降低型材挤压时的挤压力,为一些由于挤压力过高而难以挤压成形的型材提供了一种模具设计的方案。从模拟结果中可以清楚地获得挤压过程的载荷形成曲线、应力应变分布以及模具出口处的金属流速情况,便于掌握金属的流动规律,从而提高模具设计质量和效率,实现模具开发的高质量、低成本、短周期。
For the present, the use of aluminum alloy profile becomes more and more popular. Extruding method is commonly used in the production, because it can not only economize raw material, but also has high productivity. So it is taken into account increasingly. However, die design often depends on the experience and trial-and-error over and over in production. With the development of CAD/CAE in production, AL6063 alloy Lacunaris panel profile is analyzed. The porthole die are designed by using CAD software Pro/Engineer and the process of extrusion are simulated by Rigid-Plastic FEM software Deform-3D.
Firstly, design principle of the porthole die is produced, it introduces the theory of rigid-plastic FEM simply and the material flow velocity criterion. From technology and geometry aspect, the influence factor of material flow is introduced. Secondly, utilizing the method of numerical simulation to get the concrete influence of geometry factor in profile extrusion, it obtains the relationship between the bearing length and exit velocity, also it obtains the relationship between the bearing length and local extrusion ratio, the effect of major parameters of die structure on material flow velocity has been integrated and the general formula of bearing length design and calculation of Al profile extrusion have been derived. The correct controlling data are insta11ed and the simu1ation strategy are applied,for instance,to select the rational time-step,mesh fine,adjust the aberrance element,set right boundary conditions and so on,so the simulation process is carried out successfully.
It gives some innovation of the porthole die structure creatively, and put forward the idea of the porthole-expanding die and the streamline die. By analyzing the simulation results, the porthole-expanding die not only reduce the load of extrusion but also produce the alloy profile more wider than round extrusion chamber, and the streamline die can reduce the load of extrusion effectively. The data are obtained from the Post-Processor of DEFORM-3D as the graph of Load-Stroke,the effective strain and stress distribution of the work piece and the exit velocity of material flow. It must be improve the quality and efficiency of mold design and carry out the high quality, low cost and short period of mold development.
本文首先论述了平面分流组合模具的设计原则,简单介绍了刚塑性有限元理论和金属流速的判据公式,从工艺因素和几何因素方面系统介绍了影响挤压金属流动的因素。为了定量的反映几何因素在型材挤压时对金属流速的影响,利用数值模拟的方法得出了工作带长度与金属流速的关系以及局部挤压比、模孔位置、模孔的挤压工作带面积和工作带长度之间的关系。最后通过对图形文件的输入、网格细分技术,步长增量的选取以及自接触等模拟关键问题的探讨,成功地对多腔壁板铝型材挤压过程进行了模拟,得到了一组比较理想的模具参数。
本文创新性地对平面分流组合模的结构进行了一些改进,提出了分流宽展模结构和流线模结构的设计思想,为壁板类铝型材挤压模具优化设计提供了全新的思路。通过模拟分析的结果可以看到,在分流孔中进行宽展不仅降低了因为单独使用宽展模具而增加的挤压力,而且可以挤压比圆挤压筒直径更宽的壁板型材。而把流线模型应用在分流模具上可以有效的降低型材挤压时的挤压力,为一些由于挤压力过高而难以挤压成形的型材提供了一种模具设计的方案。从模拟结果中可以清楚地获得挤压过程的载荷形成曲线、应力应变分布以及模具出口处的金属流速情况,便于掌握金属的流动规律,从而提高模具设计质量和效率,实现模具开发的高质量、低成本、短周期。
For the present, the use of aluminum alloy profile becomes more and more popular. Extruding method is commonly used in the production, because it can not only economize raw material, but also has high productivity. So it is taken into account increasingly. However, die design often depends on the experience and trial-and-error over and over in production. With the development of CAD/CAE in production, AL6063 alloy Lacunaris panel profile is analyzed. The porthole die are designed by using CAD software Pro/Engineer and the process of extrusion are simulated by Rigid-Plastic FEM software Deform-3D.
Firstly, design principle of the porthole die is produced, it introduces the theory of rigid-plastic FEM simply and the material flow velocity criterion. From technology and geometry aspect, the influence factor of material flow is introduced. Secondly, utilizing the method of numerical simulation to get the concrete influence of geometry factor in profile extrusion, it obtains the relationship between the bearing length and exit velocity, also it obtains the relationship between the bearing length and local extrusion ratio, the effect of major parameters of die structure on material flow velocity has been integrated and the general formula of bearing length design and calculation of Al profile extrusion have been derived. The correct controlling data are insta11ed and the simu1ation strategy are applied,for instance,to select the rational time-step,mesh fine,adjust the aberrance element,set right boundary conditions and so on,so the simulation process is carried out successfully.
It gives some innovation of the porthole die structure creatively, and put forward the idea of the porthole-expanding die and the streamline die. By analyzing the simulation results, the porthole-expanding die not only reduce the load of extrusion but also produce the alloy profile more wider than round extrusion chamber, and the streamline die can reduce the load of extrusion effectively. The data are obtained from the Post-Processor of DEFORM-3D as the graph of Load-Stroke,the effective strain and stress distribution of the work piece and the exit velocity of material flow. It must be improve the quality and efficiency of mold design and carry out the high quality, low cost and short period of mold development.
引文
1 刘静安,谢建新. 大型铝合金型材挤压技术与工模具优化设计. 北京:冶金工业出版社,2003,1-6
2 [苏] M.3.叶尔曼诺克. 铝合金壁板挤压. 国防工业出版社. 1998,1-3
3 刘静安,轻合金挤压工具与模具(上). 北京:冶金工业出版社. 1990,19-21
4 Hyun-Woo Shin,Dong-Woo kim and Naksoo Kim A simplified three dimensional finite element analysis of the dissymmetrical extrusion processes. Journal of materials processing technology,1993,38:567-587
5 Yang D.Y.,Park K.,Kang Y.S. Integrated Finite Element Simulation for the Hot Extrusion of Complicated Al Alloy Profiles. Journal of Materials Processing Technology.2001, 111(1-3):25-30
6 J.X.Xie, T.Murakami, K. Ikeda et al. Experimental Simulation of Metal Flow in Porthole-die Extrusion. Journal of Material Processing Technology.1995, 49:1-11
7 于沪平,彭颖红,阮雪榆.平面分流焊合模成型过程的数值模拟.锻压技术,1999, 24 (5) 9-11
8 刘汉武,张志萍,王秀海,顾迎新,崔建忠,基于即遗传算法的铝型材挤压模具优化设计哈尔滨工业大学学报.2000,32 (4):86-88
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 闫洪,包忠润,柳和生 铝型材挤压模CAD/CAE/CAM研究进展.轻合金加工 技术,1999,27 (10):1-4
11 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
12 樊刚,热挤压模具设计与制造基础. 重庆:重庆大学出版社,2001:91-92
13 贾俐俐,挤压工艺与模具设计.北京:机械工业出版社,2004:194-241
14 刘静安,铝型材挤压模具设计、制造、使用及维修. 北京:冶金工业出版社,1999:118-126
15 刘静安,铝合金型材生产实用技术,重庆国际信息咨询中心,1994
16 西北铝加工厂编,挤压工具设计,1974
17 刘建生,陈慧琴,郭晓霞. 金属塑性加工有限元模拟技术与应用. 北京:冶金工业出版,2003,1-10
18 赵健,陈拂晓,上官林健. 金属体积成形模拟技术. 热加工工艺, 2001(3): 49-51
19 林新波. DEFORM-2 D和DEFORM-3D CAE软件在模拟金属塑性变形过程中的应用. 模具技术,2000(3),75-77
20 徐秉业,弹性与塑性力学,北京-机械工业出版社 1981
21 李尚健,金属塑性成形过程模拟,北京-机械工业出版社 1999
22 田柱平,郝南海。铝型材挤压模工作带形状的数值设计.模具技术,1999,No.1
23 马怀宪,挤压与拉拔,西安冶金建筑学院,1988
24 Cliff Lotvenhiser,Die Layout and Design,Processing of second intern Al Extrusion Technology. Seminar,V.2,1977,57-64
25 高济,弹塑性有限元法在非轴对称挤压变形研究中的应用,模具技术,1999,4
26 K.LAUE,H.STENGER, EXTRUSION.1976
27 Perlin,Theory of Metal Extrusion,1964
28 刘静安,轻合金挤压工具与模具,冶金工业出版社,1994
29 秦泗吉,任运来,确定挤压凹模模孔位置的局部挤压比法,塑形工程学报,1997,4(1), 67-70
30 闫洪,包忠诩,基于数值模拟的铝型材挤压变形规律的研究(I),锻压技术,2000(5),29-30
31 闫洪,包忠诩,基于数值模拟的铝型材挤压变形规律的研究(II),锻压技术,2000(6),31-32
32 林清安,Pro/ENGINEER 2001零件设计基础篇,北京-清华大学出版社 2003
33 王孟君 杨立斌. 6063 铝合金高温流变本构方程. 华中科技大学学报(自然科学版). 2003,33(6),20-22
34 王建生,许树勤,6063铝合金的热塑性实验研究,太原理工大学学报,2003,34(2),144-146
35 鲍崇桂,浅析模具结构对挤压力的影响,轻合金加工技术,2000,28(8),24-26
36 Jung Min Lee,Byung Min Kim. Effects of chamber shapes of porthole die on elastic deformation and extrusion process in condenser tube extrusion. Materials and design 26(2005) 327-336
37 席俊峰,高锦张,铝合金壁板宽展挤压模具优化设计,东南大学,硕士论文,2005
38 胡亚民,温正忠. 汽车与冷锻工艺. 汽车工艺与材料,96(12):10-11
39 郭乃成,罗子键. 圆棒热挤压过程研究. 航空学报,1992(1):7l-79
40 刘建生,陈慧琴,郭晓霞. 金属塑性加工有限元模拟技术与应用. 北京:冶金工业出版,2003,1-10
41 H.H. Jo, S.K. Lee. Prediction of welding pressure in the non-steady state porthole dies extrusion of Al7003 tubes. Machine tool & Manufacture, 2002, 753-759.
42 K.J Kim, C.H.Lee. Investigation into the improvement of welding strength in three-dimensional extrusion of tubes using porthole dies. Materials Processing Technology. 2002 426-431
43 H.H. Jo , C. S. Jeong ,Determination of welding pressure in the non-steady-state porthole die extrusion of improved Al7003 hollow section tubes. Materials Processing Technology. 2003 428-433.
44 Analysis and design of flat-die hot extrusion process 1. Three-dimensional finite element analysis. Guen-An Leea, Dae-Young Kwak. Mechanical Sciences, 2002,915-934
45 Analysis and die design of flat-die hot extrusion process 2. Numerical design of bearing lengths. Guen-An Leea, Dae-Young Kwak. Mechanical Sciences, 2002, 935-946
2 [苏] M.3.叶尔曼诺克. 铝合金壁板挤压. 国防工业出版社. 1998,1-3
3 刘静安,轻合金挤压工具与模具(上). 北京:冶金工业出版社. 1990,19-21
4 Hyun-Woo Shin,Dong-Woo kim and Naksoo Kim A simplified three dimensional finite element analysis of the dissymmetrical extrusion processes. Journal of materials processing technology,1993,38:567-587
5 Yang D.Y.,Park K.,Kang Y.S. Integrated Finite Element Simulation for the Hot Extrusion of Complicated Al Alloy Profiles. Journal of Materials Processing Technology.2001, 111(1-3):25-30
6 J.X.Xie, T.Murakami, K. Ikeda et al. Experimental Simulation of Metal Flow in Porthole-die Extrusion. Journal of Material Processing Technology.1995, 49:1-11
7 于沪平,彭颖红,阮雪榆.平面分流焊合模成型过程的数值模拟.锻压技术,1999, 24 (5) 9-11
8 刘汉武,张志萍,王秀海,顾迎新,崔建忠,基于即遗传算法的铝型材挤压模具优化设计哈尔滨工业大学学报.2000,32 (4):86-88
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 闫洪,包忠润,柳和生 铝型材挤压模CAD/CAE/CAM研究进展.轻合金加工 技术,1999,27 (10):1-4
11 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
12 樊刚,热挤压模具设计与制造基础. 重庆:重庆大学出版社,2001:91-92
13 贾俐俐,挤压工艺与模具设计.北京:机械工业出版社,2004:194-241
14 刘静安,铝型材挤压模具设计、制造、使用及维修. 北京:冶金工业出版社,1999:118-126
15 刘静安,铝合金型材生产实用技术,重庆国际信息咨询中心,1994
16 西北铝加工厂编,挤压工具设计,1974
17 刘建生,陈慧琴,郭晓霞. 金属塑性加工有限元模拟技术与应用. 北京:冶金工业出版,2003,1-10
18 赵健,陈拂晓,上官林健. 金属体积成形模拟技术. 热加工工艺, 2001(3): 49-51
19 林新波. DEFORM-2 D和DEFORM-3D CAE软件在模拟金属塑性变形过程中的应用. 模具技术,2000(3),75-77
20 徐秉业,弹性与塑性力学,北京-机械工业出版社 1981
21 李尚健,金属塑性成形过程模拟,北京-机械工业出版社 1999
22 田柱平,郝南海。铝型材挤压模工作带形状的数值设计.模具技术,1999,No.1
23 马怀宪,挤压与拉拔,西安冶金建筑学院,1988
24 Cliff Lotvenhiser,Die Layout and Design,Processing of second intern Al Extrusion Technology. Seminar,V.2,1977,57-64
25 高济,弹塑性有限元法在非轴对称挤压变形研究中的应用,模具技术,1999,4
26 K.LAUE,H.STENGER, EXTRUSION.1976
27 Perlin,Theory of Metal Extrusion,1964
28 刘静安,轻合金挤压工具与模具,冶金工业出版社,1994
29 秦泗吉,任运来,确定挤压凹模模孔位置的局部挤压比法,塑形工程学报,1997,4(1), 67-70
30 闫洪,包忠诩,基于数值模拟的铝型材挤压变形规律的研究(I),锻压技术,2000(5),29-30
31 闫洪,包忠诩,基于数值模拟的铝型材挤压变形规律的研究(II),锻压技术,2000(6),31-32
32 林清安,Pro/ENGINEER 2001零件设计基础篇,北京-清华大学出版社 2003
33 王孟君 杨立斌. 6063 铝合金高温流变本构方程. 华中科技大学学报(自然科学版). 2003,33(6),20-22
34 王建生,许树勤,6063铝合金的热塑性实验研究,太原理工大学学报,2003,34(2),144-146
35 鲍崇桂,浅析模具结构对挤压力的影响,轻合金加工技术,2000,28(8),24-26
36 Jung Min Lee,Byung Min Kim. Effects of chamber shapes of porthole die on elastic deformation and extrusion process in condenser tube extrusion. Materials and design 26(2005) 327-336
37 席俊峰,高锦张,铝合金壁板宽展挤压模具优化设计,东南大学,硕士论文,2005
38 胡亚民,温正忠. 汽车与冷锻工艺. 汽车工艺与材料,96(12):10-11
39 郭乃成,罗子键. 圆棒热挤压过程研究. 航空学报,1992(1):7l-79
40 刘建生,陈慧琴,郭晓霞. 金属塑性加工有限元模拟技术与应用. 北京:冶金工业出版,2003,1-10
41 H.H. Jo, S.K. Lee. Prediction of welding pressure in the non-steady state porthole dies extrusion of Al7003 tubes. Machine tool & Manufacture, 2002, 753-759.
42 K.J Kim, C.H.Lee. Investigation into the improvement of welding strength in three-dimensional extrusion of tubes using porthole dies. Materials Processing Technology. 2002 426-431
43 H.H. Jo , C. S. Jeong ,Determination of welding pressure in the non-steady-state porthole die extrusion of improved Al7003 hollow section tubes. Materials Processing Technology. 2003 428-433.
44 Analysis and design of flat-die hot extrusion process 1. Three-dimensional finite element analysis. Guen-An Leea, Dae-Young Kwak. Mechanical Sciences, 2002,915-934
45 Analysis and die design of flat-die hot extrusion process 2. Numerical design of bearing lengths. Guen-An Leea, Dae-Young Kwak. Mechanical Sciences, 2002, 935-946
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