CN103810306A - Efficient design method of profile extrusion mould - Google Patents
Efficient design method of profile extrusion mould Download PDFInfo
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- CN103810306A CN103810306A CN201210440992.0A CN201210440992A CN103810306A CN 103810306 A CN103810306 A CN 103810306A CN 201210440992 A CN201210440992 A CN 201210440992A CN 103810306 A CN103810306 A CN 103810306A
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Abstract
The invention discloses an efficient design method of a profile extrusion mould and belongs to the technical field of nonferrous material machining. According to the method, cross section features of a profile to be extruded are input into an expert knowledge base module; an initial mould design scheme is obtained through an expert knowledge base; pre-processed files needed for numerical simulation are automatically generated according to the mould design scheme and input into a numerical simulation module for carrying out extrusion process simulation; a numerical simulation result serves as a basis for mould structure optimization and is compared with an optimization objective function after simulation, and an optimal process scheme is designed through a process optimization module if errors exist and is verified through numerical simulation to obtain the optimal process design scheme finally. The method can significantly improve the efficiency and level of designing the profile extrusion mould and achieve efficient design of the profile extrusion mould.
Description
Technical field
The present invention relates to a kind of profile extrusion die method for designing efficiently, especially a kind of efficiently, be applicable to the method for designing of aluminium, magnesium alloy profile extrusion die, belong to nonferrous materials processing technique field.
Background technology
Design of Dies is the gordian technique that section bar extruding is produced, and is also one of bottleneck of its production of restriction.When section bar extruding, owing to being subject to the strong friction effect of die face, tap hole, seam chamber, dead band and work band, the non-uniform phenomenon of metal flow is very serious, cause the very large additonal pressure of generation in shape product, thereby produce various defects, as unstable in size, turn round stubborn, bending, wave etc., when serious, can cause that tool and mould produces wearing and tearing, plastic yield, fatigure failure and cracking etc. and lost efficacy or damaged.Therefore, reasonably design and manufacture can extend the serviceable life of mould greatly, have great importance with energy consumption to enhancing productivity, reducing costs.
Design of Dies generally comprises the evaluation of the determining of designing and calculating, size, the check of intensity and the selection of the material memory economic and technical norms of structure etc., mould is the instrument of participating in flow of metal directly, its design is different from general Course Exercise in Machinery Elements Design, but a kind of technological design between machining and pressure processing.Except will considering principle that Machine Design follows, still need and consider various technological factors under hot extrusion condition, therefore, design rationally and economic extrusion die is a very complicated and difficult job.For a long time, the domestic design for profile extrusion die rests in the accumulation of traditional dependence engineering analogy and design experiences substantially, newly-designed mould will be through die trial-repair a die-process of die trial more repeatedly, causes that mold developing cycle is long, cost is high, and product quality is difficult to guarantee.Along with aluminium profile product is constantly refined and complicated development to maximization, flat broadening, thin-walled property, height, traditional die design method cannot meet the demand of new product development pattern.
In recent years, also there is the method for numerical simulation of employing to analyze section bar extrusion process, revise Design of Dies according to numerical simulation result, replace the die trial process of workshop costliness, but the application of numerical simulation is also in larger limitation at present, the one, section bar extrusion process is and complicated METHOD FOR LARGE DEFORMATION ELASTOPLASTIC process, especially for large complicated section section bar, adopts traditional method for numerical simulation to carry out that time of simulation trial is long, efficiency is low, simulation precision is not high; The 2nd, the Extrusion Die Design based on numerical simulation is also the method for a kind of " trial and error " in fact at present, also need according to analog result, dependence designer's engineering experience is repeatedly revised die design schemes and is carried out computer simulation to verify its rationality, and this also will consume a large amount of computing times; The 3rd, while adopting business simulation softward to carry out numerical simulation, the setting up procedure of analogy model is comparatively complicated, not only require designer to possess the professional knowledges such as professional Design of Dies, processing technology, also will skillfully grasp relevant plastic forming theory and finite element simulation.Therefore, the simple profile extrusion die method for designing based on numerical simulation is difficult in actual production, be promoted and apply.
Summary of the invention
The present invention is directed to long, product quality of the design cycle that tradition " trial and error " die design method causes is difficult to control, and existing numerical simulation software is high to operating personnel's Capability Requirement, and the problems such as simulation precision is lower, computing time is long, have proposed a kind of profile extrusion die efficient design method combining based on expert knowledge library, numerical simulation technology and optimized algorithm.
First the present invention is input to expertise library module by the section bar section feature of preparing extruding production, obtain initial mould design proposal by expert knowledge library, and automatically generate the required pre-processing file of numerical simulation according to die design schemes, be input to numerical simulation module and carry out the simulation of extrusion process, numerical simulation result is as the foundation of Optimizing die structure, after simulation finishes, analog result and optimization aim function are contrasted, as exist error to utilize process optimization module, carry out the design of technique optimal case, and then verify by numerical simulation, the optimum technological design scheme of final acquisition, make process program meet design object.
The present invention adopts following technical scheme:
A kind of profile extrusion die method for designing efficiently, comprises the steps:
(1) obtain section bar characteristic information: first extract section bar characteristic information and be input in expert knowledge library;
The input of section bar characteristic information has two kinds of modes: the one, directly from expert knowledge library, retrieve section bar product of the same type, the feature modification of the line correlation of going forward side by side; The 2nd, directly import the Two-dimensional Engineering map file of section bar product, and input the characteristic information of relevant section bar by guide.
(2) technological design based on expert knowledge library: retrieve similar example take the section bar characteristic information obtaining as keyword in expert knowledge library, if retrieve similar cases, directly recall the process program of Design of Dies; If retrieval is less than similar cases, the technological design criterion and the experimental knowledge that provide by expert knowledge library complete Extrusion Die Design alternately.
(3) numerical simulation analysis: select different method for numerical simulation according to the difference of section bar section feature, then automatically generate the required pre-processing file of numerical simulation system and automatically import in numerical simulation software, utilize computing machine to complete die trial process, the last numerical simulation result of output automatically.
(4) numerical value repairs a die: judge that by numerical simulation result whether die design schemes is reasonable, and formulate the prioritization scheme of extrusion die according to analog result, instruct repairing a die in actual extrusion process.
Described section bar characteristic information comprises product material (aluminium alloy or magnesium alloy), shape facility, transverse section of section material area, maximum circumscribed circle diameter, minimum and maximum wall thickness, endoporus number and cross section complexity coefficient.
Described expert knowledge library comprises Design of Dies case library (comprising Extrusion Die Design example), process knowledge storehouse (comprising profile extrusion die design criteria and experimental knowledge) and material database (comprising section bar product classification database, aluminium alloy/magnesium alloy materials database) etc.
Described method for numerical simulation is the computing method that adopt finite element method or finite volume method and Arbitrary Lagrangian-Euler method to combine, according to the difference of section bar section feature, adopt finite element method or finite volume method to simulate in the unstable state stage of section bar extruding, and stable state compression stage adopt Arbitrary Lagrangian-Euler method to simulate without exception.
Described numerical simulation result comprises the stress of flow deformation, extrudate exit velocity, extruding force and the extrusion die of metal etc.
The described objective function repairing a die is maximum extrusion pressure, mould maximum stress in section bar exit velocity mean square deviation, extrusion process, and the objective function of extrusion die optimal design is:
(1) extrudate exit velocity mean square deviation S.D.<0.1, the computing formula of S.D. is as follows:
In formula, n is the number of grid node in extrudate outlet; v
ifor the flow velocity of i node on outlet;
for the mean flow rate of all nodes on outlet;
(2) maximum extrusion pressure F in extrusion process
maxbe less than the nominal pressure p of extruder, i.e. F
max<p;
(3) the maximum stress σ of extrusion die
maxbe less than the permissible stress σ of mold materials under working temperature
b, i.e. σ
max< σ
b.
The whole process of the inventive method comprises the input of section bar characteristic information, four steps that repair a die of technological design, Hybrid Numerical Simulation and the numerical value based on expert knowledge library.
1, the input of section bar characteristic information
For the problem that need to carry out profile extrusion die design, first extract its section bar characteristic information and be input in expert knowledge library.The input of section bar characteristic information has two kinds of modes: the one, directly from expert knowledge library, retrieve section bar product of the same type, the feature modification of the line correlation of going forward side by side; The 2nd, directly import the Two-dimensional Engineering map file of section bar product, and input the characteristic information of relevant section bar by guide.
2, the technological design based on expert knowledge library
Initial mould design is to be that similar case retrieved in keyword in expert knowledge library according to the section bar section feature obtaining, if there is similar cases, directly process program and pre-processing file are outputed to numerical simulation module, if retrieval is less than similar example, complete initial mould design technology by the data input guide of expert knowledge library.
3, Hybrid Numerical Simulation analysis
The Hybrid Numerical Simulation technology that adopts finite element method (FEM), finite volume method (FVM) and Arbitrary Lagrangian-Euler method (ALE) to combine, carries out analog simulation to section bar extrusion process, the rationality of checking die design schemes.Select different method for numerical simulation according to section bar section feature and extrusion die type, then automatically generate the required pre-processing file of numerical simulation system and automatically import in simulation softward, utilize computing machine to complete die trial process, the last numerical simulation result of output automatically.According to the difference of section bar section feature, adopt FEM or FVM to carry out numerical simulation in the unstable state stage of section bar extruding, and stable state compression stage adopt ALE to carry out numerical simulation without exception.
4, numerical value repairs a die
Judge that by numerical simulation result whether die design schemes is reasonable, and formulate the optimizing design scheme of extrusion die according to analog result, instruct repairing a die in actual extrusion process.The objective function repairing a die is respectively maximum extrusion pressure and mold stresses in section bar exit velocity mean square deviation, extrusion process, factor for profile extrusion die design overriding concern is the homogeneity that guarantees section bar exit velocity, therefore, automatically calculated the flow velocity mean square deviation of mould outlet by analog result, in the time that flow velocity mean square deviation is excessive, carry out the optimization of die design schemes according to process knowledge storehouse.In addition, also will meet the nominal pressure that maximum extrusion pressure in extrusion process should be less than extruder, the maximum stress of extrusion die is less than the permissible stress of mold materials under working temperature.
The present invention is based on expert knowledge library process design optimization is combined with numerical simulation, automatically generate the required pre-processing file of numerical simulation software, and automatically numerical simulation result is carried out to analytical calculation, generate the required criterion of optimal design module.Can reduce on the one hand the requirement of the numerical simulation technology to Design of Dies personnel, avoid the comparatively loaded down with trivial details operation of existing numerical simulation software; By abundant technological design knowledge, example in expert knowledge library, can significantly improve efficiency and the level of profile extrusion die design on the other hand, realize the efficient design of profile extrusion die.
The present invention repairs a die numerical simulation module and technological design module and optimization together with module integration, automatically generate the needed pre-processing file of simulation system by the profile extrusion die design specialist knowledge base of setting up, import in numerical simulation module, utilize numerical simulation technology to carry out virtual die trial, initial mould design proposal is analyzed, then according to objective function Automatic Optimal Design of Dies, determine the optimal case of Design of Dies, thereby reduce the technical merit requirement to technological design personnel, numerical simulation and die trial number of times are reduced, significantly shorten the Design of Dies cycle, improve the quality of extrudate.
Method of the present invention can significantly improve efficiency and the level of profile extrusion die design, realizes the efficient design of profile extrusion die.
Accompanying drawing explanation
Fig. 1 is process flow diagram of the invention process.
Fig. 2 is typical large extrusion ratio " H " for building section bar sectional dimension figure in the embodiment of the present invention.
Fig. 3 is the matching result that in the embodiment of the present invention, case retrieval goes out.
Fig. 4-a and Fig. 4-b are respectively the diffluence combination die patrix in technological design scheme and lower die structure figure in the embodiment of the present invention.
Fig. 5 is numerical simulation result output map in the embodiment of the present invention.
Fig. 6 is the Extrusion Die Design drawing of exporting in the embodiment of the present invention.
Embodiment
Below by specific embodiment, the present invention will be further described, but and do not mean that limiting the scope of the invention.
Fig. 1 is the process flow diagram that the efficient profile extrusion die method for designing of the present invention is implemented, first be the input of section bar characteristic information, can from section bar product database, retrieve section bar product of the same type, the go forward side by side feature modification of line correlation, or directly import the Two-dimensional Engineering map file of section bar product, and input the characteristic information of relevant section bar by guide.Then in expert knowledge library, retrieve similar cases, if retrieve similar cases, recall process program, if retrieval is less than similar cases, carry out the interaction design based on expert knowledge library, the technological design criterion and the experimental knowledge that in new die design process, provide by expert knowledge library complete Extrusion Die Design alternately, automatically calculate or check design parameter by system; Generate pre-processing file, output to numerical simulation module, carry out that digital simulation analysis, numerical value repair a die and actual production checking.The data storage of actual production forms expert knowledge library.
Expert knowledge library comprises Design of Dies case library, process knowledge storehouse and material database etc.Design of Dies case library comprises Extrusion Die Design example, is mainly used in storage through the qualified Design of Dies example of experimental verification and each example is carried out to sorting code number, conveniently user's calling process similarity in the time of Case Retrieval; Process knowledge storehouse comprises profile extrusion die design criteria and experimental knowledge, and conventional design criteria and experimental knowledge while being mainly used in storing Extrusion Die Design, can carry out verification to Design of Moulds, and provides reference frame for designer; Material database comprises section bar product classification database, aluminium alloy/magnesium alloy materials database, and the material properties information that is mainly used in storing section bar and mould, for follow-up numerical simulation calculation provides material model accurately and reliably.Each functional module of expert knowledge library and section bar product database are mutually integrated, realized data access between each database, are called and store by related tables of data.
Shown in Fig. 2, be typical large extrusion ratio " H " for building section bar sectional dimension figure, physical dimension is 70 × 27mm, material is Al 6061 alloys, adopts aluminium alloy bar to be shaped by diffluence combination die tool hot extrusion technique, and the present invention is as follows to the concrete steps of its Extrusion Die Design.
1, the input of section bar characteristic information
First the two-dimensional engineering graphic in section bar cross section is imported in section bar product classification database with common * .dwg form, the main information that carries out section bar cross-section analysis acquisition cross section, section bar product classification belongs to " H " section bar, dimensions is that medium section bar, transverse section of section material area are 146mm
2, maximum circumscribed circle diameter is 75mm
2, perimeter of section is 294mm
2, minimum wall thickness (MINI W.) is that 0.8mm, cross section complexity coefficient are 2.
2, the technological design based on expert knowledge library
Then section bar cross section information is delivered to Design of Dies case library, in case library, search for the case of similarity maximum as search key according to shape facility-" H " section bar, material characteristics-Al 6063 alloys, mold feature-diffluence combination die tool, technology characteristics-hot extrusion technique, size characteristic-medium section bar, be illustrated in figure 3 the similar example obtaining after retrieval, substantially mate with newly-designed section bar cross section.Its mould structure design parameter, using the basis as new designing mould, recalls technological design scheme, by the help in process knowledge storehouse, part technological parameter is modified, and obtains the Extrusion Die Design scheme of this section bar.This section bar determines that adopting diffluence combination die to carry out " mould pair goes out " pushes.As shown in Figure 4, extrusion process parameters is as follows for the upper and lower mode configuration of diffluence combination die: blank preheat temperature is that 480 ℃, mold preheating temperature are that 450 ℃, extrusion speed are 7mm/s.
3, Hybrid Numerical Simulation analysis
Because mould-type is to adopt diffluence combination die tool, therefore adopt finite volume method to carry out numerical simulation in this section bar Unsteady Extrusion Processes stage, adopt Arbitrary Lagrangian-Euler method to carry out numerical simulation in stable state compression stage, after Design of Dies completes, automatically the three-dimensional modeling of output mask is for numerical simulation, generate the required pre-processing file of simulation simultaneously automatically and carry out the numerical simulation of section bar extrusion process, due to section bar cross section symmetry, get it and 1/4 simulate.Because technological design and numerical simulation software integrate, therefore, after analog computation completes, automatically the analog result report generating by simulation softward, the analog results such as extruding force, velocity field, stress field, temperature field amount distribution plan are directly exported, designer need not directly operate and just can obtain analog result simulation softward like this, so that whether design rationally judges to mould structure.
4, numerical value repairs a die
Can find out section bar stub bar section injustice by analog result, endpiece transverse section of section material velocity distribution inequality, centre flowing velocity is obviously greater than other parts, easily causes extrusion profile buckling deformation, turns round stubborn, the unequal problem of die wear, has a strong impact on the quality of extrusion profile.So must repair a die to mould, eliminate this type of defect.Choosing section bar exit velocity according to analog result is the objective function of optimizing, and die working length is Optimal Parameters, according to the Optimized model set up and the algorithm rear mold land length design drawing that is optimized.Then re-start numerical simulation, obtain analog result as shown in Figure 5.After can finding out in figure that work band is revised, nib exit extrusion profile end face is concordant, and velocity flow profile is even.Illustrate that mould structure is reasonable in design, reached optimal design.
Finally, system is exported the relevant design drawing of this profile extrusion die automatically, as shown in Figure 6.After checking is produced in reality extruding, this technique is stored in expert knowledge library with the professional format file of two-dimensional engineering graphic, three-dimensional modeling figure, picture, document, database file form, numerical simulation software etc. respectively.
Claims (7)
1. an efficient profile extrusion die method for designing, comprises the steps:
(1) obtain section bar characteristic information: first extract section bar characteristic information and be input in expert knowledge library;
(2) technological design based on expert knowledge library: retrieve similar example take the section bar characteristic information obtaining as keyword in expert knowledge library, if retrieve similar cases, directly recall the process program of Design of Dies; If retrieval is less than similar cases, the technological design criterion and the experimental knowledge that provide by expert knowledge library complete Extrusion Die Design alternately;
(3) numerical simulation analysis: select different method for numerical simulation according to the difference of section bar section feature, then automatically generate the required pre-processing file of numerical simulation system and import in numerical simulation software, utilize computing machine to complete die trial process, the last numerical simulation result of output automatically;
(4) numerical value repairs a die: judge that by numerical simulation result whether die design schemes is reasonable, and formulate the prioritization scheme of extrusion die according to analog result, instruct repairing a die in actual extrusion process.
2. efficient profile extrusion die method for designing according to claim 1, is characterized in that: described section bar characteristic information comprises product material, shape facility, transverse section of section material area, maximum circumscribed circle diameter, minimum and maximum wall thickness, endoporus number and cross section complexity coefficient.
3. efficient profile extrusion die method for designing according to claim 1, it is characterized in that: described section bar characteristic information input comprises two kinds of modes: the one, directly from expert knowledge library, retrieve section bar product of the same type, the feature modification of the line correlation of going forward side by side; The 2nd, directly import the Two-dimensional Engineering map file of section bar product, and input the characteristic information of relevant section bar by guide.
4. efficient profile extrusion die method for designing according to claim 1, is characterized in that: described expert knowledge library comprises section bar product classification database, aluminium alloy/magnesium alloy materials database, profile extrusion die design criteria and Extrusion Die Design example.
5. efficient profile extrusion die method for designing according to claim 1, it is characterized in that: described method for numerical simulation is the computing method that adopt finite element method or finite volume method and Arbitrary Lagrangian-Euler method to combine, according to the difference of section bar section feature, adopt finite element method or finite volume method to simulate in the unstable state stage of section bar extruding, and stable state compression stage adopt Arbitrary Lagrangian-Euler method to simulate.
6. efficient profile extrusion die method for designing according to claim 1, is characterized in that: described numerical simulation result comprises the stress of the flow deformation of metal, extrudate exit velocity, extruding force and extrusion die.
7. efficient profile extrusion die method for designing according to claim 1, is characterized in that: described in the objective function that repairs a die be:
(1) extrudate exit velocity mean square deviation S.D.<0.1, the computing formula of S.D. is as follows:
In formula, n is the number of grid node in extrudate outlet; v
ifor the flow velocity of i node on outlet;
for the mean flow rate of all nodes on outlet;
(2) maximum extrusion pressure F in extrusion process
maxbe less than the nominal pressure p of extruder, i.e. F
max<p;
(3) the maximum stress σ of extrusion die
maxbe less than the permissible stress σ of mold materials under working temperature
b, i.e. σ
max< σ
b.
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| CN104647697A (en) * | 2015-01-27 | 2015-05-27 | 苏州汇众模塑有限公司 | Digital design technology for injection mold |
| CN104951590A (en) * | 2015-04-20 | 2015-09-30 | 广东工业大学 | Knowledge service system and method for die designing |
| CN105039805A (en) * | 2015-07-08 | 2015-11-11 | 山东裕航特种合金装备有限公司 | Manufacturing method of aluminum alloy mechanical arm track girder hollow profile |
| CN106372279A (en) * | 2016-08-22 | 2017-02-01 | 中国航空工业集团公司西安飞机设计研究所 | Extruded profile mark screening method |
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| CN104951590A (en) * | 2015-04-20 | 2015-09-30 | 广东工业大学 | Knowledge service system and method for die designing |
| CN105039805A (en) * | 2015-07-08 | 2015-11-11 | 山东裕航特种合金装备有限公司 | Manufacturing method of aluminum alloy mechanical arm track girder hollow profile |
| CN105039805B (en) * | 2015-07-08 | 2017-05-17 | 山东裕航特种合金装备有限公司 | Manufacturing method of aluminum alloy mechanical arm track girder hollow profile |
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| CN107808064B (en) * | 2017-11-22 | 2021-04-27 | 武汉理工大学 | Optimization design method of short-flow extrusion forming process of blast furnace tuyere front-end cap body |
| CN107808064A (en) * | 2017-11-22 | 2018-03-16 | 武汉理工大学 | The Optimization Design of the short route extrusion forming process of blast-furnace tuyere front end cap body |
| CN108595763A (en) * | 2018-03-26 | 2018-09-28 | 武汉理工大学 | Die assembly design method based on model index technology |
| CN108388676A (en) * | 2018-03-27 | 2018-08-10 | 广东工业大学 | A kind of mold data matching process, apparatus and system based on simulated annealing |
| CN110968921A (en) * | 2018-09-27 | 2020-04-07 | 中山市华盛家具制造有限公司 | Automatic simulation board packaging process method in furniture industry |
| CN110968921B (en) * | 2018-09-27 | 2023-06-20 | 广东华盛家具集团有限公司 | Automatic simulation board packaging process method in furniture industry |
| CN110851920A (en) * | 2019-05-15 | 2020-02-28 | 成都数模码科技有限公司 | Automatic generation method for main rib line of die pressing device |
| CN110750931A (en) * | 2019-10-18 | 2020-02-04 | 徐州工业职业技术学院 | Efficient section bar extrusion die design method |
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