CN112464428B - Design method of copper alloy special-shaped profile extrusion die - Google Patents
Design method of copper alloy special-shaped profile extrusion die Download PDFInfo
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Abstract
The invention provides a design method of a copper alloy special-shaped section extrusion die, which belongs to the technical field of copper alloy special-shaped section processing and comprises the following steps: performing numerical simulation of a product extrusion process on a copper alloy profile extrusion die with the same height of a straight wall at all positions by using deform simulation software; the speed distribution of the extruded product is determined through the numerical simulation result; setting nodes on the same cross section of the product at the outlet of the extrusion die, extracting the speed of each node, and calculating the standard difference sigma of the speed of each node; predicting the bending and twisting condition of the product according to the sigma value; according to the bending condition of the product, the height of a straight wall of the area with the fastest blank flow speed is increased; and obtaining a plurality of standard deviation values sigma through a plurality of times of simulation, wherein the straight wall height corresponding to the minimum standard deviation value is the optimal straight wall height. The design method of the extrusion die balances the flow velocity of metal at different positions of the section interface, eliminates the bending defect of a copper alloy extruded product, and improves the quality of the finished product.
Description
Technical Field
The invention belongs to the technical field of copper alloy special-shaped profile processing, and particularly relates to a design method of an extrusion die for processing a copper alloy profile with a complex cross-sectional shape.
Background
The copper alloy is formed by adding one or more other elements into pure copper serving as a matrix, and has excellent electrical conductivity, thermal conductivity, ductility, wear resistance and corrosion resistance. So that the method has wide application prospect in the industrial fields of electronics, traffic, aerospace, weaponry and the like.
The section bar is a solid straight bar material which is formed by plastic processing and has certain section shape and size. In the section products, except for simple section shapes such as square, round and flat steel and the like and symmetry about a centroid, most sections have complex sections, wherein the section shapes of the special-shaped sections have no symmetry characteristic, even the centroid is not in the section, and the defects of bending, torsion and the like can occur during extrusion forming of a conventional die.
The flow law of the metal in the extrusion die mainly follows the law of minimum resistance: the metal will preferentially flow to the areas with low resistance, so that the metal flow rate is high in the areas with low friction resistance. For the section with a regular shape, the friction resistance of each area is balanced when the blank is processed, namely the influence of the friction resistance on the forming quality is small; when the sectional shape of the special-shaped profile is not symmetrical, the frictional resistance has great influence on the forming quality of the blank. When the heights of the straight walls of the extrusion die hole are the same, the areas of the side walls corresponding to the areas with different shapes on the side wall of the die hole are different, so that the metal in the area with large contact area with the flowing metal is large in friction resistance, and the metal in the area with small contact area is small in friction resistance. The imbalance of the friction force distribution causes the metal on the same cross section to generate larger flow speed difference, and the extruded product is easy to have the bending defect, thereby causing the quality and the precision of the formed product to be reduced and improving the processing cost.
At present, in the design of a special-shaped profile extrusion die, the problem that defects are caused by the fact that flow velocity of each area in the extrusion process is not uniform is solved by researchers as follows: the person Guo superior of Guangdong Jianmei aluminum profile (group) limited in 2017 invented a method for arranging multiple diversion holes, and the design idea of the method is to balance the metal flowing speed of each part by changing the size and the relative position of the diversion holes. The method for arranging the asymmetric shunting holes can improve the quality problem of extruded special-shaped profiles, but the method is not suitable for solid special-shaped profiles because the problem of intersection of a plurality of welding lines in a welding chamber can occur in extrusion forming, and the quality of products is seriously influenced; the other method is a method proposed by rank of the university of major continuous engineering: a chamfer is formed at the entrance of the extrusion die hole, and after the upper and lower structures of the extrusion die hole are changed, the metal generates plastic flow at different rates. Furthermore, shear stress can be introduced into the metal in the forming process, and the method can improve the plasticity of the product and has lower manufacturing cost. However, for the special-shaped section with a complex shape, the flow rate of each part of the metal cannot be balanced only by chamfering, and the processed product still has the bending defect, so the method is not suitable for the special-shaped section with a complex shape.
In conclusion, in order to improve the bending defect of the extruded product and improve the product quality, the invention provides a design scheme of an extrusion die for ensuring that metal has no bending defect, and the processing quality of the solid special-shaped profile product is greatly improved.
Disclosure of Invention
The invention aims to provide a design method of a copper alloy special-shaped section extrusion die, which is used for eliminating the bending and twisting defects in the process of extruding a special-shaped section.
In order to achieve the purpose, the invention provides the following scheme:
a design method of a copper alloy special-shaped section extrusion die is characterized by comprising the following steps: the method comprises the following steps:
s1: performing numerical simulation of a product extrusion process on a copper alloy profile extrusion die with the same height of a straight wall at all positions by using deform simulation software;
s2: the speed distribution of the extruded product is determined through the numerical simulation result;
s3: and setting nodes on the same cross section of the product at the outlet of the extrusion die, extracting the speed of each node, and calculating the standard difference value of the speed of each node.
V in formula (1) i The flow speed of the blank at the ith node on the cross section,
the average speed of all nodes considered on the section is shown, and n is the total number of the nodes taken by the section;
s4: predicting the bending and twisting condition of the product according to the sigma value;
s5: according to the bending condition of the product, the height of a straight wall of the area with the fastest blank flow speed is increased;
s6: and obtaining a plurality of standard deviation values sigma through a plurality of times of simulation, wherein the straight wall height corresponding to the minimum standard deviation value is the optimal straight wall height.
The technical scheme of the invention is further improved as follows: in the deform simulation in step S1, the straight wall height of the extrusion die is set to a value of 3mm to 5mm with the extrusion die having a uniform straight wall height as a reference.
The technical scheme of the invention is further improved as follows: the nodes selected in step S3 need to ensure that each area has 2 or 3 nodes and all the nodes are uniformly distributed.
The technical scheme of the invention is further improved as follows: when the height of the straight wall is increased to a certain value in step S5, due to the effect of the blank twisting defect, the utilization rate of the increased straight wall is reduced, that is, the standard deviation σ of the speed is increased, so that the height of the straight wall at the bending direction of the product is increased, the reduction of the utilization rate of the straight wall of the extrusion die is avoided, and the uniform metal flow velocity at the same section of the product is ensured, that is, the standard deviation σ is minimum. Due to the adoption of the technical scheme, the invention has the technical effects that:
in the forming process of the metal section, different positions of the side wall of the same extrusion section cause non-uniform metal flow rate due to different friction resistance, thereby generating the bending defect. In order to balance the metal flow velocity of each area, the invention adjusts the height of the straight wall of different areas at the outlet of the extrusion die through numerical simulation, namely, the height of the straight wall of the area with higher flow velocity is increased, the height of the straight arm of the area with lower flow velocity is reduced, the flow velocity of the metal at different positions of the same section of the profile is balanced, and the bending defect of an extruded part is eliminated.
Compared with the existing special-shaped profile extrusion die, the extrusion die provided by the invention can eliminate the bending defect of an extruded product, does not consume extra production cost and has high production efficiency.
Drawings
FIG. 1 is an isometric view of an extrusion die for copper alloy special-shaped profiles according to example 1 of the present invention;
FIG. 2 is a schematic structural view of an extrusion die for copper alloy special-shaped profiles according to embodiment 1 of the present invention;
FIG. 3 is a left side view of FIG. 2;
FIG. 4 is a bottom view of FIG. 2;
FIG. 5 is a drawing of an extrusion die of a copper alloy profile according to example 1 of the present invention.
Fig. 6 shows the node positions of the extrusion die for copper alloy special-shaped profiles in embodiment 1 of the invention.
FIG. 7 is a front view showing the result of an extrusion simulation of a copper alloy special-shaped profile with a uniform vertical wall height of 5mm in example 1 of the present invention;
FIG. 8 is a left side view of the extrusion simulation result of the copper alloy special-shaped profile with a uniform vertical wall height of 5mm in example 1 of the present invention;
FIG. 9 is a top view showing the result of the extrusion simulation of the copper alloy special-shaped section with a uniform vertical wall height of 5mm in example 1 of the present invention;
FIG. 10 is a copper alloy special-shaped section extrusion die with a straight wall height of 20mm in the upper area of example 1 of the present invention;
FIG. 11 is a front view showing the result of an extrusion simulation of a copper alloy profile having a straight wall height of 20mm in the upper region according to example 1 of the present invention;
FIG. 12 is a left side view showing the result of the extrusion simulation of the copper alloy deformed section bar having a straight wall height of 20mm in the upper region according to example 1 of the present invention;
FIG. 13 is a top view showing the result of an extrusion simulation of a copper alloy deformed section having a straight wall height of 20mm in the upper region according to example 1 of the present invention;
FIG. 14 is a front view showing the result of an extrusion simulation of a copper alloy deformed section in which the height of the straight wall in the upper region is 30mm, the height of the straight wall in the lower region is 20mm, and the height of the straight wall in the remaining region is 5mm according to example 1 of the present invention;
FIG. 15 is a left side view showing the extrusion simulation result of the copper alloy deformed section bar of example 1 of the present invention, in which the height of the straight wall in the upper region is 30mm, the height of the straight wall in the lower region is 20mm, and the height of the straight wall in the remaining region is 5 mm;
FIG. 16 is a top view showing the result of an extrusion simulation of a copper alloy shaped material according to example 1 of the present invention, wherein the height of the straight wall in the upper region is 30mm, the height of the straight wall in the lower region is 20mm, and the height of the straight wall in the remaining region is 5 mm;
wherein: 1. upper region, 2, right region, 3, lower region, 4, left region.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings and the specific embodiments. It should be apparent that the described embodiment is only one embodiment of the invention, and not all embodiments. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Example 1
As shown in fig. 5, which is a drawing of the copper alloy special-shaped profile extrusion product to be obtained, fig. 1 is a drawing of the copper alloy special-shaped profile extrusion die, in this embodiment, in order to simplify the adjustment process, the straight wall height which is equal everywhere at the first numerical simulation is designed to be the minimum value: 5mm, as shown in fig. 7-9, the simulation results obtained by deform show that the upper and lower parts of the test piece have bending defects due to uneven friction, and the analysis can obtain: the metal flow rate is fastest when the billet is in contact with the upper zone 1; the metal flow rate at which the billet is in contact with the lower zone 3 is slightly slower than the metal flow rate at the upper zone 1; the right and left zone 2, 4 flow rates are much less than the metal flow rate at the upper zone 1. In addition, when the product is extruded out of the extrusion die outlet, nodes are provided on the surface contacting with the extrusion die straight wall, as shown in fig. 6, the velocity of each node is extracted, and the standard deviation σ of the velocity is calculated according to the formula (1) to obtain σ 1 ＝39.739。
In the present embodiment, if the height of the straight wall of the upper region 1 where the metal flow rate is the fastest is increased to 20mm, as shown in fig. 10, the simulation results shown in fig. 11 to 13 are obtained by numerical simulation, and when a work is extruded from the extrusion die outlet, nodes are provided on the surface contacting with the straight wall of the extrusion die, as shown in fig. 6, the velocity of each node is extracted, and the standard deviation σ of the velocity is calculated according to the formula (1), to obtain σ 2 28.144. According to the simulation result and the speed standard deviation, the height of the straight wall has a certain relieving effect on the bending defect of the workpiece, but the expected effect is not achieved.
Based on the above analysis results, the height of the straight wall in the upper region 1 was designed to be 30mm, the height of the straight wall in the lower region 3 was designed to be 20mm, and the height of the straight wall in the right region 2 and the left region 4 was constant, as shown in FIG. 1The simulation results shown in fig. 14-16 are obtained after the row number simulation. When the product is extruded out of the extrusion die outlet, nodes are arranged on the surface contacting with the extrusion die straight wall, as shown in fig. 6, the speed of each node is extracted, and the standard deviation sigma of the speed is calculated according to the formula (1) to obtain sigma 3 ＝14.923。
By comparing and analyzing the simulation results and the speed standard deviation values of fig. 7-9, 11-13 and 14-16, the extrusion die for the special-shaped test piece can set the height of the straight wall in different areas according to the metal flow characteristics (namely the minimum resistance law), so that the bending defect of the test piece in the extrusion process can be effectively relieved.
In this embodiment, the extrusion simulation performed by adjusting the height of the straight wall for a plurality of times shows that the standard deviation σ of the velocity is 14.923 as the minimum, and therefore, the height of the straight wall in the upper region 1 is determined to be 30mm, the height of the straight wall in the lower region 3 is determined to be 20mm, and the height of the straight wall in the right region 2 and the left region 4 is determined to be 5mm, which is the best solution of the present design method.
In this embodiment, carry out inclined plane transition processing between upper portion region 1 and right part region 2, the left part region 4 at the extrusion die exit, the contained angle between inclined plane and the finished piece direction of motion is 20, carries out the fillet processing at the extrusion die entrance, and fillet radius is 3 mm.
The principles and embodiments of this invention have been described herein using specific examples, the foregoing description of which is provided to assist in understanding the invention and its core; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (1)
1. A design method of a copper alloy special-shaped profile extrusion die is characterized by comprising the following steps: the method comprises the following steps:
s1: performing numerical simulation of a product extrusion process on copper alloy profile extrusion dies with equal height positions of the straight wall through deform simulation software;
s2: the speed distribution of the extruded product is determined through the numerical simulation result;
s3: setting nodes on the same cross section of the product at the outlet of the extrusion die, extracting the speed of each node, and calculating the standard difference sigma of the speed of each node;
v in formula (1) i The flow speed of the blank at the ith node on the cross section,
the average speed of all nodes considered on the section is shown, and n is the total number of the nodes taken by the section;
s4: predicting the bending and twisting condition of the product according to the sigma value;
s5: according to the bending condition of the product, the height of the straight wall of the area with the fastest flow rate of the blank is increased;
s6: obtaining a plurality of standard deviation values sigma through a plurality of times of simulation, wherein the height of the straight wall corresponding to the minimum standard deviation value is the optimal height of the straight wall;
in the step S1, when performing the Deform simulation, the straight wall height of the extrusion die is set to a value of 5mm with reference to the extrusion die having a uniform straight wall height;
the nodes selected in step S3 need to ensure that each area has 2 or 3 nodes, and all the nodes are uniformly distributed;
when the height of the straight wall is increased to a certain value in step S5, due to the effect of the blank twisting defect, the utilization rate of the increased straight wall is reduced, that is, the standard deviation σ of the speed is increased, so that the height of the straight wall at the bending direction of the product is increased, the reduction of the utilization rate of the straight wall of the extrusion die is avoided, and the uniform metal flow velocity at the same section of the product is ensured, that is, the standard deviation σ is minimum.
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| CN108889786A (en) * | 2018-05-29 | 2018-11-27 | 广东工业大学 | A kind of aluminum extrusion process energy consumption optimization method based on numerical simulation |
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| US8257623B2 (en) * | 2009-08-27 | 2012-09-04 | Corning Incorporated | Extrusion die flow modification and use |
| CN103678772B (en) * | 2013-11-13 | 2017-09-22 | 内蒙古工业大学 | A kind of method for numerical simulation for analyzing extrusion die Length discrepancy work band structure size |
| JP6809202B2 (en) * | 2016-12-20 | 2021-01-06 | 日本製鉄株式会社 | Hot water surface shape estimation method and hot water surface shape estimation device |
| CN110362861B (en) * | 2019-06-10 | 2023-05-02 | 广东工业大学 | Multi-objective optimization method for mold structural parameters in consideration of energy efficiency |
| CN111637058B (en) * | 2020-05-25 | 2021-06-25 | 中南大学 | Aluminum alloy impeller of Roots blower, extrusion die and extrusion process |
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|---|---|---|---|---|
| CN101604350A (en) * | 2009-07-15 | 2009-12-16 | 北京科技大学 | A kind of numerical simulation technology for hollow section porthole die extrusion welding process |
| CN103810306A (en) * | 2012-11-07 | 2014-05-21 | 北京有色金属研究总院 | Efficient design method of profile extrusion mould |
| CN108889786A (en) * | 2018-05-29 | 2018-11-27 | 广东工业大学 | A kind of aluminum extrusion process energy consumption optimization method based on numerical simulation |
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