不同模型腔角下铜铝复合连续包覆过程的数值模拟

Numerical Simulation of Continuous Extrusion Cladding Copper-Al under Die Different Diversion Angle

利用有限元软件对铜铝复合连续包覆成形过程进行二维有限元数值模拟,详细研究了不同模具模型腔角下金属的流动规律、挤压力、模具载荷、应力、应变分布的影响规律。结果表明,在30°～60°的型腔角度中,模型腔角越小,金属流动越均匀,挤压力越小,越有利于节省能耗、降低成本。从包覆复合的结合面质量方面考虑,模型腔角越小越有利。从防止应力集中,保护模具角度考虑,应选择小的模型腔角。从变形效率方面来说,模型腔角越小越好。在TLJ400连续挤压机上进行了铜铝复合的连续包覆工艺试验,试验结果与数值模拟结果相符合。

The continuous extrusion cladding forming process of the Cu-A1 wire was simulated by a two- dimensional FEM software to analyze metal flow, velocity distribution, the effective stress and strain dis- tribution under die different diversion angle. The results show that with decreasing in diversion angle, metal flow exhibits more homogeneous, and extruding force is decreased, which is beneficial for saving energy and reducing cost. In addition, small diversion angle is helpful for improving the cladding quality of Cu-AI wire, and for decreasing stress aggregation to improve mould as well as for increasing deforma- tion efficiency. The continuous extrusion forming of Cu-A1 was conducted on TLJ400 extruded machine, and the experimental results are well in agreement with the simulated ones.