Cross-section distortion and springback characteristics of double-cavity aluminum profile in force controlled stretch-bending

3D elastic-plastic FE model for simulating the force controlled stretch-bending process of double-cavity aluminum profile was established using hybrid explicit−implicit solvent method.Considering the computational accuracy and efficiency,the optimal choices of numerical parameters and algorithms in FE modelling were determined.The formation mechanisms of cross-section distortion and springback were revealed.The effects of pre-stretching,post-stretching,friction,and the addition of internal fillers on forming quality were investigated.The results show that the stress state of profile in stretch-bending is uniaxial with only a circumferential stress.The stress distribution along the length direction of profile is non-uniform and the maximum tensile stress is located at a certain distance away from the center of profile.As aluminum profile is gradually attached to bending die,the distribution characteristic of cross-section distortion along the length direction of profile changes from V-shape to W-shape.After unloading the forming tools,cross-section distortion decreases obviously due to the stress relaxation,with a maximum distortion difference of 13%before and after unloading.As pre-stretching and post-stretching forces increase,cross-section distortion increases gradually,while springback first decreases and then remains unchanged.With increasing friction between bending die and profile,cross-section distortion slightly decreases,while springback increases.Cross-section distortion decreases by 83%with adding PVC fillers into the cavities of profile,while springback increases by 192.2%.

Flexible bending of aluminum profiles with polyurethane pad

The high flexibility of profile bending with hyperelastic pad enables it to be a promising method for small lot or single part production, especially for space frame and roof-rail parts in automotive and aerospace industries. Bending of two aluminum profiles with different sections was carried out to investigate the effect of main process parameters on the bending process. Results show that the shape of the cross-section and its relative thickness and section modulus in bending are the main factors that determine the bending properties of the profiles. Roller stroke, properties of polyurethane pad and constraints on profiles are key factors that determine the bending radius and section deformation of bent profiles. Failures and quality problems met in experiments were also analyzed.

Study on inhomogeneous cooling behavior of extruded profile with unequal and large thicknesses during quenching using thermo-mechanical coupling model

The interfacial heat transfer coefficient between hot profile surface and cooling water was determined by using inverse heat conduction model combined with end quenching experiment. Then, a Deform-3 D thermo-mechanical coupling model for simulating the on-line water quenching of extruded profile with unequal and large thicknesses was developed. The temperature field, residual stress field and distortion of profile during quenching were investigated systematically. The results show that heat transfer coefficient increases as water flow rate increases. The peak heat transfer coefficient with higher water flow rates appears at lower interface temperatures. The temperature distribution across the cross-section of profile during quenching is severe nonuniform and the maximum temperature difference is 300 ℃ at quenching time of 3.49 s. The temperature difference through the thickness of different parts of profile first increases sharply to a maximum value, and then gradually decreases. The temperature gradient increases obviously with the increase of thickness of parts. After quenching, there exist large residual stresses on the inner side of joints of profile and the two ends of part with thickness of 10 mm. The profile presents a twisting-type distortion across the cross-section under non-uniform cooling and the maximum twisting angle during quenching is 2.78°.

Detection of butt weld of laser-MIG hybrid welding of thin-walled profile for high-speed train

Purpose–This study aims to solve the problem of weld quality inspection,for the aluminum alloy profile welding structure of high-speed train body has complex internal shape and thin plate thickness(2–4 mm),the conventional nondestructive testing method of weld quality is difficult to implement.Design/methodology/approach–In order to solve this problem,the ultrasonic creeping wave detection technology was proposed.The impact of the profile structure on the creeping wave detection was studied by designing profile structural test blocks and artificial simulation defect test blocks.The detection technology was used to test the actual welded test blocks,and compared with the results of X-ray test and destructive test(tensile test)to verify the accuracy of the ultrasonic creeping wave test results.Findings–It is indicated that that X-ray has better effect on the inspection of porosities and incomplete penetration defects.However,due to special detection method and protection,the detection speed is slow,which cannot meet the requirements of field inspection of the welding structure of aluminum alloy thin-walled profile for high-speed train body.It can be used as an auxiliary detection method for a small number of sampling inspection.The ultrasonic creeping wave can be used to detect the incomplete penetration welds with the equivalent of 0.25 mm or more,the results of creeping wave detection correspond well with the actual incomplete penetration defects.Originality/value–The results show that creeping wave detection results correspond well with the actual non-penetration defects and can be used for welding quality inspection of aluminum alloy thin-wall profile composite welding joints.It is recommended to use the echo amplitude of the 10 mm 30.2 mm 30.5 mm notch as the criterion for weld qualification.

KEY TECHNIQUES IN R&D OF OUT-SIZE EXTRUSION PRESS WITH OIL-DRIVEN DOUBLE ACTION

A modem design method, in which traditional design formulas are conjoined with numerical simulation and optimization, is successfully used to design the out-size extrusion flame precisely so that the press cost can be saved. A new technology used for decompressing by a multi-steps dynamical mode is put forward, which makes it possible to decompress the large flow-volume high-pressure oil in the main cylinders. In addition, a method for realizing the fixed mandrel process by hydraulic support is proposed and its control equation is established. Pre-tightening frame tests are carried out by over-operating pressure on 100 MN aluminium extrusion press with oil-driven double action, which is developed based on the above key techniques and is the largest press so far in the world, and the results show that the frame structure designed is reasonable and reliable, and the modem design method used is an useful tool for designing large and out-size heavy plastic forming machinery. The results of decompressing curve in main cylinder and noise inspection indicate that multi-steps dynamical mode for decompressing the large flow-volume high pressure oil is valid and reliable. Meanwhile, the fixed mandrel process is well realized based on the control equation. These key techniques have been used in the development of 125 MN aluminium extrusion press with oil-driven double action.