scholarly journals Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1517 ◽  
Author(s):  
Zhiwen Liu ◽  
Luoxing Li ◽  
Shikang Li ◽  
Jie Yi ◽  
Guan Wang

The design of a porthole die is one of the key technologies for producing aluminum profiles. For an aluminum profile with high length–width ratio and small cavity, it is difficult to control the metal flow through porthole die with the same velocity to ensure the die’s strength. In the present study, the porthole die extrusion process of aluminum profile with small cavity was simulated using HyperXtrude 13.0 software based on ALE formulation. The simulation results show for the traditional design scheme, the metal flow velocity in porthole die at every stage was severely not uniform. The standard deviation of the velocity (SDV) at the die exit was 19.63 mm/s. The maximum displacement in the small mandrel was 0.0925 mm. Then, aiming at achieving a uniform flow velocity and enough die strength, three kinds of die structure modifications for the porthole die were proposed. After optimization, desired optimization results with SDV of 0.448 mm/s at the die exit and small mandrel deflection were obtained. Moreover, the temperature uniformity on the cross-section of die exit, welding pressure, and die strength were improved greatly. Finally, the optimal porthole die was verified by the real extrusion experiment. A design method for porthole die for aluminum with a high length–width ratio and small cavity was proposed, including sunken port bridges to rearrange the welding chamber in upper die, increasing the entrance angle of portholes, introducing the baffle plate, and adjusting the bearing length.

2010 ◽  
Vol 44-47 ◽  
pp. 311-315
Author(s):  
Hao Chen ◽  
Guo Qun Zhao ◽  
Cun Sheng Zhang ◽  
Dao Sheng Wen

The shape of welding chamber is a key parameter in flat porthole die extrusion process, which influences product quality and die life-span directly. In this paper, by means of numerical simulation of the extrusion process for an aluminum hollow profile, the effects of multi-step welding chamber on metal flow and die strength have been investigate. The numerical results revealed that the multi-step welding chamber was effective to balance metal flow in the die cavity. In addition, with an increasing step of welding chamber, the maximum stress and deflection of the lower die decreased, while the deflection of the mandrel kept almost unchanged and the maximum stress of upper die increased.


2013 ◽  
Vol 457-458 ◽  
pp. 156-159
Author(s):  
Fu Li Lu ◽  
Ji Shun Song ◽  
Jian Zhang

This paper describes a 3D-deform simulation of porthole die extrusion process for producing harmonica-shaped tubes used for a cooling system of automobiles. Designing the related structure of the porthole die and observing the simulation results, the study was designed to evaluate the welding effect when the length of bearing exit take different values.The mean pressure and exit velocity at the welding plane are analyzed at the same time. The welding effect is determined by the mean pressure at the welding plane .The behavior of metal flow in the container is analyzed in this paper. Through the above analysis, the best structure and size can be obtained in the process of deformation so as to obtain the better machanical properties.


2011 ◽  
Vol 479 ◽  
pp. 62-73 ◽  
Author(s):  
Quang Cherng Hsu ◽  
Kun Hong Kuo ◽  
Chi Peng Hsu

Direct extrusion by porthole – bridge die configuration has been successfully used to fabricate products with hollow cross sections for 6000 series aluminum alloys. However, if for 7000 series aluminum alloys, this situation alerts since different alloy composition such as Cu causing hollow extrusion failed due to not enough welding strength in seam. In order to determine the solid welding conditions during hollow extrusion with porthole die structure for high strength aluminum alloy, an easy tooling configuration has been designed. The proposed method is easy and cheap because there is no necessary to conduct experiment in controlled environment such as in vacuum chamber of Gleeble test or in a protective atmosphere. A seam and hollow extrusion for square tube has been conducted to obtain the welding strength comparison to the proposed solid welding method which shows good agreement.


2017 ◽  
Vol 93 (5-8) ◽  
pp. 2791-2799 ◽  
Author(s):  
Jixiao Zhang ◽  
Liang Chen ◽  
Guoqun Zhao ◽  
Cunsheng Zhang ◽  
Jixue Zhou

2011 ◽  
Vol 291-294 ◽  
pp. 290-296
Author(s):  
Lei Cheng ◽  
Shui Sheng Xie ◽  
You Feng He ◽  
Guo Jie Huang ◽  
Yao Fu

FEM simulation of aluminum profiles in porthole die extrusion process using Lagrange mesh description will inevitably bring mesh self-contact, severe grid distortion and frequent remeshing, which will result in the loss of computational accuracy and excessive calculation time. In order to solve the above mentioned problems, numerical simulation of aluminum profiles with large and complicated cross-section in extrusion process was achieved using finite volume method based on Euler mesh description. The metal flow behavior and welding course was investigated in detail, which can provide the theoretical guide for porthole die design and optimization. In addition, extrusion experiment was carried out by numerical simulation results. The experimental extrudate was in good agreement with the simulation results, which laid a good solid foundation for non-steady state extrusion process analysis of large scale and complicated cross-section profiles.


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