CN110968934A - Computer simulation method for aluminum extrusion process - Google Patents
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- 238000001125 extrusion Methods 0.000 title claims abstract description 168
- 238000000034 method Methods 0.000 title claims abstract description 57
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 21
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 21
- 238000005094 computer simulation Methods 0.000 title claims abstract description 13
- 238000004519 manufacturing process Methods 0.000 claims abstract description 20
- 238000010438 heat treatment Methods 0.000 claims abstract description 9
- 238000004088 simulation Methods 0.000 claims description 10
- 235000012438 extruded product Nutrition 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 238000003825 pressing Methods 0.000 claims description 6
- 238000005457 optimization Methods 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 230000001419 dependent effect Effects 0.000 claims description 3
- 238000006073 displacement reaction Methods 0.000 claims description 3
- 230000000704 physical effect Effects 0.000 claims description 2
- 238000004364 calculation method Methods 0.000 description 9
- 238000009826 distribution Methods 0.000 description 4
- 238000005266 casting Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004422 calculation algorithm Methods 0.000 description 1
- 239000013256 coordination polymer Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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Abstract
The invention discloses a computer simulation method for an aluminum extrusion process, which comprises the following steps: s1: simulating the heating process of the extrusion container, and judging whether the simulated temperature meets a set threshold value; s2: simulating non-production auxiliary time, and extruding the cast ingot by the extrusion shaft according to a preset extrusion speed; s3: repeating the step S1 and the step S2 to obtain extrusion characteristic data and process data of the extruded aluminum product; s4: the computer-aided module calculates the parameter coefficients and selects the optimal temperature gradient. The invention can conveniently obtain the optimal temperature gradient of the extruded ingot blank by simulating extrusion and a computer auxiliary module.
Description
Technical Field
The invention relates to the field of aluminum extrusion, in particular to a computer simulation method for an aluminum extrusion process.
Background
The existing production process is not controlled by a modern computer system, and the realization of the full-automatic production is simple and hard to imagine. Computers have become an indispensable tool for modern production management and operation and maintenance throughout the entire production process, i.e. from the plant and any unused programmable controllers, via manual process data input and automatic process optimization, to the management of production data and the storage of process data, etc.
It is very important to accurately study the temperature field of the aluminum extrusion process. Variations in the conditions of use and process flow lead to large differences in the temperature field, especially in the temperature variation and temperature rise in the extruder barrel and deformation zone. Although the temperature at a single point can be measured, it is difficult to obtain details of the distribution of the temperature field throughout the process, and it is not possible to obtain the optimum temperature gradient of the extruded ingot, and information on various parameters in the extrusion process.
Disclosure of Invention
The invention aims to provide a computer simulation method for an aluminum extrusion process aiming at the defects of the background technology and the existing design, and the design can conveniently obtain the optimal temperature gradient of an extruded ingot blank through a simulation extrusion module and a computer auxiliary module and detect the corresponding parameter information in the extrusion process.
A computer simulation method for an aluminum extrusion process, comprising:
s1: simulating the heating process of the extrusion container, and judging whether the simulated temperature meets a set threshold value;
s2: simulating non-production auxiliary time, and extruding the cast ingot by the extrusion shaft according to a preset extrusion speed;
s3: repeating the step S1 and the step S2 to obtain extrusion characteristic data and process data of the extruded aluminum product;
s4: the computer-aided module calculates the parameter coefficients and selects the optimal temperature gradient.
Further, the extrusion characteristic data includes a maximum extrusion force, a maximum extrusion shaft travel speed, and a non-productive assistance time; the process data comprises the size specification of the extrusion ingot, the size specification of the extrusion container, the product specification, the used die, the physical properties of the alloy, the outlet speed of the extruded product, the extrusion temperature of the front end of the ingot and the rear end of the ingot when the ingot is put in, the temperature of the extrusion container, the maximum extrusion force during extrusion and the minimum extrusion force during extrusion.
Further, the step S1 includes the following steps:
if the simulation temperature reaches the preset temperature of the extrusion container, the extrusion container starts to operate;
if the simulated temperature exceeds the preset temperature of the extrusion container, stopping the extrusion container;
and if the simulated temperature does not reach the preset temperature of the extrusion container, continuing heating the extrusion container.
Further, the step S2 requires that a steady flow extrusion condition be satisfied, i.e., that the extrusion speed be less than or equal to the maximum extrusion shaft speed.
Further, the step S4 includes:
s41: the computer-aided module calculates the average shear force during the extrusion process:
ΔF＝Fmax-Fmin
wherein, taum0For shear stress, FmaxMaximum extrusion force in extrusion, FminIs the minimum extrusion force during extrusion, DaIs the diameter of the extrusion container, ΔsIs the displacement of the extrusion shaft;
s42: at the end of the extrusion, the temperature increase in the insulating state due to the deformation is ΔT0：
Wherein, Delta T0To be extrudedThe temperature rise in the insulating state caused by the deformation is shown, rho is the metal density, CPIs the specific heat capacity of the extruded metal;
Kfas a function of the extrusion temperature, speed and degree of deformation, Kf0For pressing the finished Kf，Kf1At other time intervals Kf；
ΔT1Temperature rise in an insulating state at other time periods; u is the extrusion coefficient, VsFor the speed of movement of the extrusion axis, T0Non-extrusion time.
S43: the computer-aided module selects the optimal temperature gradient according to the calculated parameter coefficient.
Further, the step S42 includes:
k dependent on extrusion speed, temperature and degree of deformationfThe regression equation of (A) calculates K reflecting the situation at the end of extrusionf0For other time periods, the computer-aided module also calculates KfAnd Kf1The value of (d);
adiabatic temperature rise DeltaT in the deformation zone of the production site1As shown in the following formula:
the temperature increase in the deformation zone causes the temperature increase in the deformation zone at the production site, and after deducting a certain amount of heat dissipated to the die, the product outlet temperature from the start of extrusion to the end of extrusion can be calculated to perform a series of optimization operations, so that the temperature value and the maximum extrusion force of the extruder cannot be exceeded during extrusion.
The invention has the beneficial effects that: the invention provides a simulation method and a program, which can obtain the optimal temperature gradient of an extruded ingot blank through simulation extrusion and a computer auxiliary module and detect corresponding parameter information in the extrusion process.
Drawings
FIG. 1 is a workflow of an optimization procedure;
FIG. 2 is a schematic diagram of the partitioning of components in a two-dimensional thermal simulation of forward extrusion according to the finite element method;
FIG. 3 is a workflow diagram in simulation operation;
FIG. 4 is a graph of the temperature at the inner diameter of the inner sleeve profile;
FIG. 5 is a graph showing a relationship between a pressing force and a pressing stroke in aluminum pressing;
FIG. 6 is a computer aided forward extrusion time program optimized data acquisition system.
Detailed Description
In order to more clearly understand the technical features, objects, and effects of the present invention, specific embodiments of the present invention will now be described with reference to the accompanying drawings.
In this embodiment, as shown in fig. 1, a computer simulation method for an aluminum extrusion process includes:
s1: simulating the heating process of the extrusion container, and judging whether the simulated temperature meets a set threshold value;
s2: simulating non-production auxiliary time, and extruding the cast ingot by the extrusion shaft according to a preset extrusion speed;
s3: repeating the step S1 and the step S2 to obtain extrusion characteristic data and process data of the extruded aluminum product;
s4: the computer-aided module calculates the parameter coefficients and selects the optimal temperature gradient.
In this embodiment, as shown in fig. 5, a two-dimensional model is studied, that is, the heat source and the temperature variation in the radial and axial directions of the extrusion tool and the billet are considered at the same time. The input information mainly includes alloy components, properties and variety specifications of the material; the starting temperatures of all components and the relevant process parameters that may have an influence on the extrusion process. At the same time, effective boundary conditions should be determined, and these data can usually be looked up from the relevant database. The relevant calculations are performed by means of a finite element method.
As shown in fig. 2, the component division of the extrusion container, billet, die and the like in the extrusion process is shown. A large number of components, in particular a large number of components divided in the extrusion cylinder, is necessary for accurately determining the temperature field inside the extrusion cylinder, but requires a very complicated and time-consuming calculation.
The working process of the simulation operation is shown in fig. 3:
the first stage simulates the barrel heating process, and when the thermocouple detects that the element has reached a specified temperature, the extruder is ready for operation, and if the simulated temperature exceeds (or does not reach) a specified tolerance value, the barrel heating is stopped or continued.
The second stage simulates the non-extrusion (production) assist time. Heat is dissipated under ambient conditions that do not extend over the production time.
In the third stage, the extrusion shaft extrudes the ingot at a specified extrusion speed until a residue remains. In order to satisfy the condition of steady-flow extrusion, the extrusion speed must not exceed a prescribed maximum value.
After repeated simulation extrusion in the second stage and the third stage, the simulation extrusion calculation can be carried out for any times.
FIG. 4 shows the axial temperature distribution on the inner diameter of the inner jacket when a 6063 ingot is forward extruded at an extrusion temperature of 470 ℃ (the rated temperature of the extrusion cylinder is 440 ℃) in a 22MN extruder. The continuous curve indicates the temperature profile measured immediately after the container has been heated.
The temperature profiles before the 20 th, 40 th and 60 th extrusion are shown in fig. 4, respectively. As is clear from the figure, a quasi-steady thermal state occurs after the 20 th extrusion. The large number of measurements of the temperature distribution on the inner diameter of the inner jacket also shows that the calculated temperature distribution is consistent with reality, but the actual measurement and calculation process is very time consuming and expensive.
For simplicity, the maximum possible product exit velocity obtained with the existing extrusion pressure and the specified maximum product exit temperature can be used to determine the optimum temperature gradient of the extruded billet used.
The following models were available for the study:
a. using a basic meta-disk model;
b. using a single-dimensional model and performing calculations according to a finite element method, wherein radial heat flow in the casting blank is considered;
c. a two-dimensional-like model is used, the calculations of which are the same as for the one-dimensional method. The heat flow between the extrusion axis and the rear end of the cast strand is taken into account;
d. a simplified two-dimensional finite element method process is used. In all of the above processes, only the boundary temperature of the inner jacket of the extrusion cylinder is predefined for the extrusion cylinder. Based on the detailed two-dimensional model, the internal relation of the physics aspects of the four models can be mastered, and a numerical algorithm is developed.
Regardless of the model used, the process conditions for extruding a commercially available product in an aluminum extrusion plant with a specific die can be recorded by means of a measuring position detection device.
As shown in fig. 5, the average shear force is:
ΔF＝Fmax-Fmin
wherein, taum0For shear stress, FmaxMaximum extrusion force in extrusion, FminIs the minimum extrusion force during extrusion, DaIs the diameter of the extrusion container, ΔsIs the displacement of the extrusion shaft;
at the end of the extrusion, the temperature increase in the insulating state due to the deformation is ΔT0：
Wherein, Delta T0P is the metal density, C, for the extrusion to end the temperature rise in the insulating state due to deformationPIs the specific heat capacity of the extruded metal;
Kfas a function of the extrusion temperature, speed and degree of deformation, Kf0For pressing the finished Kf，Kf1At other time intervals Kf；
ΔT1Temperature rise in an insulating state at other time periods; u is the extrusion coefficient, VsFor the speed of movement of the extrusion axis, T0Non-extrusion time.
From the above graphs it can be seen that the average shear should be τm0And a temperature increase (temperature rise) Δ T at the end of extrusion without heat transfer (insulation)0In accordance with the calculated value given by the computer, the temperature of the deformation zone of other time periods can be calculated by means of the computer. Accurate average shear stress, extrusion shaft advance speed, and boundary temperature of the inner liner of the extrusion barrel are required for accurate calculation.
In the test, the two groups of data are shown for the first time to be unstable and not consistent with the rated temperature of the extrusion container.
Empirical formulas that depend on such parameters as extrusion time, assist (non-productive) time, extrusion barrel temperature rating, etc. will be used in calculating the boundary temperature. To develop these equations, the operation was performed using a container temperature calculation program.
The temperature of the deformation zone at the time can thus be determined. From the extrusion speed, temperature and deformation rangeDegree dependent KfK reflecting the situation of the extrusion end time can be calculated in the regression equationf0For all other time periods, K may likewise be determinedfAnd Kf1The numerical value of (c). Adiabatic temperature increase (temperature rise) Δ T in the deformation zone of the production site1As shown in the following formula:
the temperature in the deformation zone is increased in the production field, and after deducting a certain amount of heat dissipated to the die, the product outlet temperature (which means the average temperature of the cross section of the extruded product) from the beginning to the end of extrusion can be calculated to perform a series of optimization operations, so that the temperature and the maximum extrusion force of the extruder cannot be exceeded during extrusion.
For changing the initial heating temperature and the extrusion speed of the ingot, the magnitude of the average shear force, the deformation heat, and the extrusion pressure should be determined. This can be achieved from
Is derived from the ratio of (a) to (b), where K isfBoth depending on the temperature and speed of production in situ.
S53: and the computer auxiliary module selects the temperature gradient of the minimum temperature difference according to the calculated parameter coefficient.
When the temperature gradient and the running speed of the extrusion shaft are different when the cast ingot is put into the extruder, the limit of the extrusion force and the outlet temperature of the extruded product is considered, and the variation (variable) calculation is adopted. If a larger billet temperature gradient is used that results in an equal maximum product exit velocity, the program should select a temperature gradient that results in a minimum temperature differential in the extruded product (see FIG. 1).
As shown in FIG. 6, a measuring position acquisition system apparatus was installed in an extrusion plant in Germany for the purpose of checking and improving the simulation program. Thereby, various extrusion parameters under production conditions can be continuously accepted and collected. The temperature of the extruded ingot was measured from five places with a pyrometer. The pyrometers are mounted so that they can be moved in a horizontal direction, so that the test points are distributed uniformly and can also be used when changing the strand length. The thermocouple can be pressed onto the extruded ingot blank by means of a compressed air cylinder, and the results displayed by the system substantially correspond to the measured data.
When the temperature gradient and the running speed of the extrusion shaft are different when the ingot casting ingot is put into the extruder, the deformation calculation is adopted in consideration of the limitation of the extrusion force and the temperature of the outlet of the extruded product. The computer-aided module selects a temperature gradient that produces the least temperature difference in the extruded product if a greater billet temperature gradient is used that results in an equal maximum product exit velocity.
The foregoing shows and describes the general principles and broad features of the present invention and advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and are only illustrative of the principles of the present invention, but that various changes and modifications may be made without departing from the spirit and scope of the invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (6)
1. A computer simulation method for an aluminum extrusion process, comprising:
s1: simulating the heating process of the extrusion container, and judging whether the simulated temperature meets a set threshold value;
s2: simulating non-production auxiliary time, and extruding the cast ingot by the extrusion shaft according to a preset extrusion speed;
s3: repeating the step S1 and the step S2 to obtain extrusion characteristic data and process data of the extruded aluminum product;
s4: the computer-aided module calculates the parameter coefficients and selects the optimal temperature gradient.
2. The aluminum extrusion process computer simulation method of claim 1, wherein the extrusion characteristic data includes a maximum extrusion force, a maximum extrusion shaft travel speed, and a non-production assist time; the process data comprises the size specification of the extrusion ingot, the size specification of the extrusion container, the product specification, the used die, the physical properties of the alloy, the outlet speed of the extruded product, the extrusion temperature of the front end of the ingot and the rear end of the ingot when the ingot is put in, the temperature of the extrusion container, the maximum extrusion force during extrusion and the minimum extrusion force during extrusion.
3. The method for computer simulation of an aluminum extrusion process according to claim 1, wherein the step S1 includes the steps of:
if the simulation temperature reaches the preset temperature of the extrusion container, the extrusion container starts to operate;
if the simulated temperature exceeds the preset temperature of the extrusion container, stopping the extrusion container;
and if the simulated temperature does not reach the preset temperature of the extrusion container, continuing heating the extrusion container.
4. The method for computer simulation of an aluminum extrusion process according to claim 1, wherein the step S2 requires satisfying a steady flow extrusion condition that the extrusion speed is less than or equal to the maximum extrusion shaft speed.
5. The method for computer simulation of an aluminum extrusion process according to claim 1, wherein the step S4 includes:
s41: the computer-aided module calculates the average shear force during the extrusion process:
ΔF＝Fmax-Fmin
wherein, taum0For shear stress, FmaxMaximum extrusion force in extrusion, FminTo minimize the extrusion force during extrusion, DaIs the diameter of the extrusion container, ΔsIs the displacement of the extrusion shaft;
s42: in the extrusionAt the end, the temperature increase in the insulating state due to the deformation is ΔT0：
Wherein, Delta T0P is the metal density, C, for the extrusion to end the temperature rise in the insulating state due to deformationPIs the specific heat capacity of the extruded metal;
Kfas a function of the extrusion temperature, speed and degree of deformation, Kf0For pressing the finished Kf，Kf1At other time intervals Kf；
ΔT1Temperature rise in an insulating state at other time periods; u is the extrusion coefficient, VsFor the speed of movement of the extrusion axis, T0Non-extrusion times.
S43: the computer-aided module selects the optimal temperature gradient according to the calculated parameter coefficient.
6. The method for computer simulation of an aluminum extrusion process according to claim 5, wherein the step S42 includes:
k dependent on extrusion speed, temperature and degree of deformationfThe regression equation of (A) calculates K reflecting the situation at the end of extrusionf0For other time periods, the computer-aided module also calculates KfAnd Kf1The value of (d);
adiabatic temperature rise DeltaT in the deformation zone of the production site1As shown in the following formula:
the temperature increase in the deformation zone causes the temperature increase in the deformation zone at the production site, and after deducting a certain amount of heat dissipated to the die, the product outlet temperature from the start of extrusion to the end of extrusion can be calculated to perform a series of optimization operations, so that the temperature value and the maximum extrusion force of the extruder cannot be exceeded during extrusion.
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