薄壁矩形管铝型材分流挤压过程挤压力影响研究

Study on influence of extrusion force during split extrusion process forthin-walled rectangular tube aluminum profile

以6063铝合金薄壁矩形管为研究对象,首先应用Deform-3D模拟软件分析成形过程中的材料流动与挤压力的变化规律及原因;其次,基于正交试验研究不同工艺参数对挤压力的影响及显著性。结果表明:挤压初期材料处于镦粗和填充状态,挤压力显著上升,而当材料经分流孔进入焊合室后被焊合,分流金属接触到焊合室底部后在焊合室内不断聚集并横向移动,导致挤压力急剧增大;挤压力随坯料温度与模具温度的升高而降低,随挤压速度的增加而增大。最后,基于优选的因素水平,模拟获得了较低的挤压力,将该值与基于主应力法获取的理论最大挤压力进行对比,模拟值与理论值的误差为5.6%。研究成果可为铝型材多孔分流挤压的省力成形和提高模具寿命提供依据。

For 6063 aluminum alloy thin-walled rectangular tube,firstly,the changing rules and causes of material flow and extrusion force during the forming process were analyzed by simulation software Deform-3D,and secondly,based on orthogonal test,the influences and significance of different process parameters on the extrusion force were investigated.The results show that in the early state of extrusion,the material is in a state upsetting and filling,and the extrusion force increases significantly.The material is welded after entering the welding chamber through the shunt hole,and the shunt metal contacts the bottom of welding chamber and continues to gather and move laterally in the welding chamber,which causes the extrusion force to increase sharply.The extrusion force decreases with the increasing of billet temperature and mold temperature,and increases with the increasing of extrusion speed.Finally,based on the preferred factors and levels,the lower extrusion force is obtained by the simulation.This value is compared with the theoretical maximum extrusion force obtained based on the principal stress method,and the error between the simulation and theoretical values is 5.6%.Thus,the research results provides the basis for realizing labor-saving forming of porous split extrusion for aluminum profile and improving the life of mold.