WO2021248748A1 - 变通道转角自弯曲挤压模具及其设计、制造和挤压方法 - Google Patents

变通道转角自弯曲挤压模具及其设计、制造和挤压方法 Download PDF

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WO2021248748A1
WO2021248748A1 PCT/CN2020/118504 CN2020118504W WO2021248748A1 WO 2021248748 A1 WO2021248748 A1 WO 2021248748A1 CN 2020118504 W CN2020118504 W CN 2020118504W WO 2021248748 A1 WO2021248748 A1 WO 2021248748A1
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axis
extrusion die
bending
cavity
self
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PCT/CN2020/118504
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French (fr)
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朱光明
闵范磊
常征
刘惠苹
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山东理工大学
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/08—Making wire, bars, tubes
    • B21C23/12—Extruding bent tubes or rods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/001—Extruding metal; Impact extrusion to improve the material properties, e.g. lateral extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/002—Extruding materials of special alloys so far as the composition of the alloy requires or permits special extruding methods of sequences
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/02—Dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/10—Making tools by operations not covered by a single other subclass
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/17—Mechanical parametric or variational design

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  • the present disclosure relates to the technical field of molds, in particular to a variable-channel corner self-bending extrusion mold and its design, manufacturing and extrusion methods.
  • Bent aluminum profiles are widely used in aerospace, automotive, machinery manufacturing, shipbuilding and chemical industries. With the rapid development of industrial economy, there is an increasing demand for bent aluminum structural parts in various fields. Generally, the processing of bent profiles is first The way of bending after extrusion, the traditional secondary processing techniques such as push bending, stretch bending, bending and roll bending will bring defects such as aluminum profile cracking, cross-sectional distortion, instability wrinkling and springback, which will seriously affect the bending of aluminum profile. The molding rate.
  • the streamlined extrusion die makes the extrusion process into a perfect material flow under specific materials and process conditions, resulting in small strain energy and low extrusion load, that is, it is adaptable, but the streamlined extrusion die design It is more difficult to process. It is mostly used in the design of simple symmetrical extrusion dies, and the function is limited to straight aluminum extrusions.
  • the purpose of the present disclosure is to provide a variable channel corner self-bending extrusion die and its design, manufacturing and extrusion methods, so as to alleviate the technical problems of springback, wrinkling and cross-sectional deformation during profile bending processing in the prior art, and to reduce extrusion The technical problem of the load during compression.
  • the present disclosure provides a method for designing a variable channel corner self-bending extrusion die, which includes the following steps:
  • the central axis of the cavity of the symmetrical streamline extrusion die is twisted and deformed in a certain plane to form an arched curve; wherein the arched curve remains symmetrical along the extrusion direction, and has no offset at both ends of the curve and is aligned with the axis.
  • a working belt structure is added behind the cavity of the variable channel corner self-bending extrusion die, and the wall surface of the working belt structure is parallel to the extrusion direction.
  • the step of designing a symmetric streamline extrusion die based on a sine function further includes:
  • the cavity of the extrusion die remains circular along any horizontal cross-section.
  • the boundary curve of the extrusion die cavity is described by a sine function, with the center of the central axis as the origin, the z direction as the extrusion direction, and the left line function as described by :
  • R is the diameter of the inlet die hole, that is, the diameter of the blank
  • r is the diameter of the outlet die hole, that is, the diameter of the bar
  • L is the height of the mold cavity.
  • the step of twisting and deforming the cavity center axis of the symmetric streamline extrusion die on a certain plane further includes:
  • the Axis_trig of the distorted central axis Axis is described as follows based on the trigonometric function:
  • h is the maximum offset distance of the twisted and deformed central axis curve
  • the step of twisting and deforming the cavity center axis of the symmetric streamline extrusion die on a certain plane further includes:
  • the Axis_gauss of the distorted central axis Axis is described as follows based on the Gaussian-like distribution function:
  • Axis_gauss0 A exp(-B ⁇ z 2 )
  • a and B are undetermined coefficients.
  • Axis_gauss (h+Axis_gauss0(L/2))exp(B ⁇ z 2 )-Axis_gauss0(L/2)
  • the value of the coefficient B is an empirical value, and when the value of B is 0.01, the distance from the end of the curve to the original axis can be controlled within 0.01 mm.
  • establishing the cavity wall equation of the variable channel corner self-bending extrusion die includes the following steps:
  • the cavity wall is described as a curved surface equation:
  • Axis is Axis_trig or Axis_gauss respectively.
  • the present disclosure provides a method for manufacturing a variable channel corner self-bending extrusion die, which is manufactured based on the design method of the variable channel corner self-bending extrusion die.
  • variable channel corner self-bending extrusion die which is manufactured by the method for manufacturing the variable channel corner self-bending extrusion die, and includes: a die body;
  • the mold body includes a mold cavity and a work belt structure; the mold cavity has a self-bending outlet, the work belt structure extends along the self-bending outlet of the mold cavity, and the work belt structure is integrated with the mold cavity connect;
  • the wall surface of the cavity is a curved surface equation:
  • the central axis equation of the cavity is described as follows based on a trigonometric function:
  • h is the maximum offset distance of the twisted and deformed central axis curve
  • the value of the coefficient B is an empirical value, and when the value of B is 0.01, the distance from the end of the curve to the original axis can be controlled within 0.01mm;
  • Axis is Axis_trig or Axis_gauss respectively.
  • the present disclosure provides an extrusion method based on the variable channel corner self-bending extrusion die, which includes the following steps:
  • the speed of extruding metal is controlled at the entrance of the mold cavity, and under the limitation of the self-bending exit of the mold cavity and the working belt structure, the extruded metal forms a curved profile with a preset curvature.
  • the present disclosure provides a method for designing a variable channel corner self-bending extrusion die, which includes the following steps: designing a symmetrical streamlined extrusion die based on a sine function, the two side walls of the extrusion die cavity are symmetrical streamlined; The axis of the cavity of the extrusion die is twisted and deformed on a certain plane to form an arched curve; among them, the arched curve remains symmetrical along the extrusion direction, with no offset at both ends of the curve and tangent to the axis; according to the arch Establish the cavity wall equation of the self-bending extrusion die with variable channel corners on the central axis of the shape curve; add a working belt structure behind the cavity of the self-bending extrusion die with variable channel corners, and the wall of the working belt structure is parallel to the extrusion direction; Design and form a variable channel corner self-bending extrusion die; after the metal flows through the variable channel corner self-bending extrusion die, the cavity of the variable channel corner self-bending extrusion die
  • FIG. 1 is a schematic diagram of the overall structure of a variable channel corner self-bending extrusion die provided by an embodiment of the disclosure
  • FIG. 2 is a schematic diagram of the cavity structure of the die body of the variable channel corner self-bending extrusion die provided by an embodiment of the present disclosure
  • FIG. 3 is a schematic diagram of the numerical calculation results of the profile formed by the extrusion of the variable channel corner self-bending extrusion die provided by the embodiment of the disclosure.
  • Icon 1-Mold body; 11-Mold cavity; 12-Working belt structure; 2-Mold cavity geometry; 21-Middle axis of symmetrical extrusion die; 22-Left contour of symmetrical extrusion die; 23-Symmetry The right contour line of the type extrusion die; 24-the central axis of the variable channel corner self-bending extrusion die; 25-the left contour line of the variable channel corner self-bending extrusion die; 26-the right side of the variable channel corner self-bending extrusion die Contour line; 31-extruded curved profile.
  • this embodiment combines the profile extrusion and bending integrated forming process with a streamlined extrusion die, and proposes a new process of variable channel corner self-bending extrusion forming, by designing a streamlined extrusion die structure with a twisted central axis , To make the metal flow unevenly in the cavity, so as to directly extrude the curved profile.
  • the method for designing a variable channel corner self-bending extrusion die includes the following steps: designing a symmetrical streamlined extrusion die based on a sine function, the extrusion die cavity 11
  • the two side walls of the symmetrical streamlined extrusion die are symmetrical and streamlined; the center axis of the cavity 11 of the symmetrical streamlined extrusion die is twisted and deformed in a certain plane to form an arched curve; wherein the arched curve remains symmetrical along the extrusion direction, The two ends of there are no offset and are tangent to the axis; according to the central axis of the arched curve, the wall equation of the cavity 11 of the variable channel corner self-bending extrusion die is established; behind the cavity 11 of the variable channel corner self-bending extrusion die A working belt structure 12 is added, and the wall surface of the working belt structure 12 is parallel to the extrusion direction.
  • the method for designing a variable channel corner self-bending extrusion die includes the following steps: designing a symmetric streamlined extrusion die based on a sine function, and the two side walls of the extrusion die cavity 11 are symmetrical streamlined; The central axis of the cavity 11 of the symmetrical streamlined extrusion die is twisted and deformed in a certain plane to form an arched curve; wherein the arched curve remains symmetrical along the extrusion direction, with no offset at both ends of the curve and tangent to the axis ; According to the central axis of the arched curve, establish the wall equation of the cavity 11 of the variable channel corner self-bending extrusion die; add the working belt structure 12 behind the cavity 11 of the variable channel corner self-bending extrusion die, and the working belt structure 12 The wall surface is parallel to the extrusion direction; the design forms a variable channel corner self-bending extrusion die; after the metal flows through the variable channel corner self-bending extrusion die, the cavity 11 of the variable channel corner
  • the step of designing a symmetric streamline extrusion die based on a sine function also includes: the shape of the cavity 11 of the extrusion die along any horizontal section Keep a circle, the boundary curve of the extrusion die cavity 11 is described by a sine function, with the center of the central axis 21 of the symmetric extrusion die as the origin, the z direction is the extrusion direction, and the left contour of the symmetric extrusion die
  • the function of 22 is described as:
  • R is the diameter of the inlet die hole, that is, the diameter of the blank
  • r is the diameter of the outlet die hole, that is, the diameter of the bar
  • L is the height of the mold cavity 11.
  • the step of twisting and deforming the center axis of the cavity 11 of the symmetric streamline extrusion die on a certain plane further includes: the Axis_trig of the twisted center axis Axis is described as follows based on a trigonometric function:
  • h is the maximum offset distance of the twisted and deformed central axis curve.
  • the step of twisting and deforming the central axis of the cavity 11 of the symmetrical streamline extrusion die on a certain plane further includes:
  • the Axis_gauss of the distorted central axis Axis is described as follows based on the Gaussian-like distribution function:
  • Axis_gauss0 A exp(-B ⁇ z 2 )
  • a and B are undetermined coefficients.
  • the center axis of distortion is the center axis 24 of the self-bending extrusion die with variable channel corners.
  • Axis_gauss (h+Axis_gauss0(L/2))exp(B ⁇ z 2 )-Axis_gauss0(L/2)
  • the value of the coefficient B is an empirical value, and when the value of B is 0.01, the distance from the end of the curve to the original axis can be controlled within 0.01 mm.
  • establishing the wall equation of the cavity 11 of the variable channel corner self-bending extrusion die includes the following steps:
  • the wall surface of the cavity 11 is described as a curved surface equation:
  • Axis is Axis_trig or Axis_gauss respectively.
  • the boundary curve of the symmetrical streamlined cavity 11 is described by a sine function, which is symmetrical
  • the center of the central axis 21 of the extrusion die is taken as the origin, and the z direction is the extrusion direction, then the function Line_left of the left contour line 22 of the symmetrical extrusion die is described as:
  • Axis_gauss of the central axis 24 of the self-bending extrusion die with variable channel angle based on the Gauss-like distribution function is described as:
  • Axis_gauss (10+0.1832)exp(0.01 ⁇ z 2 )-0.1832
  • variable channel angle is determined from the equation Axis of the central axis 24 of the bending extrusion die, that is, after the central axis of the symmetrical streamlined cavity 11 is twisted and deformed, the other parameters of the cavity 11 structure will be translated accordingly, that is, the cavity before the deformation
  • the shape along a certain horizontal section remains circular.
  • variable channel corner mold cavity 11 wall surface equation for:
  • the central axis 24 of the variable channel corner self-bending extrusion die is:
  • This embodiment provides a method for manufacturing a variable channel corner self-bending extrusion die, which is manufactured based on the design method of the variable channel corner self-bending extrusion die; this embodiment uses the variable channel corner according to the above design method
  • the curved surface equation of the wall surface of the mold cavity 11 is mechanically fabricated, and then a self-bending extrusion die with variable channel corners can be fabricated.
  • variable channel corner self-bending extrusion die which is manufactured by the method for manufacturing the variable channel corner self-bending extrusion die, and includes: a die body 1;
  • the mold body 1 includes a mold cavity 11 and a work belt structure 12; the mold cavity 11 has a self-bending outlet, the work belt structure 12 extends along the self-bending outlet of the mold cavity 11, and the work belt structure 12 is integrally connected with the mold cavity 11;
  • the wall surface of the cavity 11 is a curved surface equation:
  • the central axis equation of the cavity 11 is described as follows based on the trigonometric function:
  • h is the maximum offset distance of the twisted and deformed central axis curve
  • the value of the coefficient B is an empirical value, and when the value of B is 0.01, the distance from the end of the curve to the original axis can be controlled within 0.01mm;
  • Axis is Axis_trig or Axis_gauss respectively.
  • adding the working belt structure 12 can extend the coordination of metal deformation, reduce the difference in metal flow speed in the channel of the working belt structure 12, reduce the unevenness of the extrusion speed, and thus change the degree of bending. It is small, so the working belt structure 12 is added, which can be used to design the extrusion of profiles with different curvatures.
  • This embodiment provides an extrusion method based on the variable channel corner self-bending extrusion die, which includes the following steps: accommodating metal in the cavity 11 of the die body 1; at the entrance of the cavity 11 The speed of extruding the metal is controlled at the location, and under the limitation of the self-bending exit of the mold cavity 11 and the working belt structure 12, the extruded metal forms a curved profile with a preset curvature, thereby forming an extruded curved profile 31.
  • the temperature is 470°C
  • the preheating temperature of the extrusion die is 480°C
  • the shear friction model is used between the blank and the die
  • the friction factor is set to 0.7
  • the Coulomb friction model is used between the blank and the working belt
  • the friction factor is set to 0.3, according to the symmetry
  • the simulation is performed on 1/2 of the entire model, all components are divided into tetrahedral elements, the number of blank meshes is 30,000, and the displacement step length is 0.2mm.
  • the numerical calculation is performed on the extruded curved profile 31 formed by the variable channel corner self-bending extrusion die of the embodiment of the present disclosure.
  • the simulation result is a schematic diagram of the deformed body mesh.
  • the metal flow rate at the outlet is linearly distributed, and the profile will naturally bend to the side with the slower flow rate when extruding the profile to realize the natural bending and forming of the bar profile aluminum alloy, and then extrude high-quality products with a certain arc at one time.
  • the compressive load is lower than that of traditional molds.
  • the strain is always greater on the same horizontal line as it goes to the left, that is, the strain of the metal on the convex side of the mold (left side) is greater than that on the concave side of the mold (right side)
  • the strain of) reaches its maximum value at the exit of the die, so the deformation on the left is always greater than that on the right. Due to the coordination of metal deformation, the extruded profile bends to the right.

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Abstract

一种变通道转角自弯曲挤压模具及其设计、制造和挤压方法，涉及模具的技术领域，包括以下步骤：设计基于正弦函数的对称流线型挤压模具；对称流线型挤压模具的模腔（11）中轴线在某一平面进行扭曲变形；建立变通道转角自弯曲挤压模具的模腔（11）壁面方程；在变通道转角自弯曲挤压模具的模腔（11）后面增设工作带结构（12）；金属流经变通道转角自弯曲挤压模具后，控制挤出速度呈线性分布，从而直接挤压出弯曲件，因此型材不受横向力矩，从而使型材外侧面减小或者杜绝截面变形，而且金属在挤压过程中发生的流动比传统阶梯型挤压模具更加顺畅，挤压载荷变低；缓解了现有技术中存在的型材弯曲加工时回弹、起皱和截面变形的技术问题以及降低挤压时的载荷的技术问题。

Description

变通道转角自弯曲挤压模具及其设计、制造和挤压方法
相关申请的交叉引用
本公开要求于2020年06月08日提交中国专利局的申请号为CN202010520555.4、名称为“变通道转角自弯曲挤压模具及其设计、制造和挤压方法”的中国专利申请的优先权，其全部内容通过引用结合在本公开中。
技术领域
本公开涉及模具技术领域，尤其是涉及一种变通道转角自弯曲挤压模具及其设计、制造和挤压方法。
背景技术
弯曲铝型材广泛应用于航空航天、汽车、机械制造、船舶及化学工业等领域中，随着工业经济的飞速发展，各领域对弯曲铝型材结构件的需求日益增多，通常弯曲型材的加工采用先挤压后弯曲的方式，传统的推弯、拉弯、折弯和滚弯等二次加工技术会带来铝型材开裂、截面畸变、失稳起皱和回弹等缺陷，严重影响弯曲铝型材的成型率。
现有技术中采用挤压弯曲一体化成型，在挤压模具后安装由环形圆盘或辊子组成的弯曲装置，金属挤出后直接进入弯曲装置，实现型材的弯曲变形。相比传统工艺，该工艺结合了压力弯弧与滚压弯弧的优点，可使回弹或起皱弯弧不稳等缺陷减小，但横向力矩的存在使得这些缺陷不能根本上避免，而且弯曲通道外侧会对挤压出的金属产生阻力，弯弧较大或挤压速度较快时，型材外侧面受到较大应力容易导致截面变形。
另一方面，流线型挤压模具在特定的材料和工艺条件下，使挤压过程变成完美的材料流动，产生的应变能小，挤压载荷低，即具有适应性，但流线型挤压模具设计与加工较为困难，多用于简单对称型挤压模具的设计上，而且功能上只限于挤出直的铝型材。
发明内容
本公开的目的在于提供变通道转角自弯曲挤压模具及其设计、制造和挤压方法，以缓解现有技术中存在的型材弯曲加工时回弹、起皱和截面变形的技术问题以及降低挤压时的载荷的技术问题。
本公开提供的一种变通道转角自弯曲挤压模具设计方法，包括以下步骤：
设计基于正弦函数的对称流线型挤压模具，所述挤压模具模腔的两侧壁面为对称流线 型；
对所述对称流线型挤压模具的模腔中轴线在某一平面进行扭曲变形，形成一拱形曲线；其中，拱形曲线保持沿挤压方向对称，在曲线的两端无偏移且与轴线相切；
根据拱形曲线的中轴线，建立变通道转角自弯曲挤压模具的模腔壁面方程；
在变通道转角自弯曲挤压模具的模腔后面增设工作带结构，工作带结构的壁面与挤压方向平行。
在本公开较佳的实施例中，设计基于正弦函数的对称流线型挤压模具的步骤还包括：
挤压模具的模腔沿任意水平截面的形状保持圆形，挤压模具模腔的边界曲线由正弦函数描述，以中轴线的中心作为原点，设z方向为挤压方向，左边线函数描述为：
Figure PCTCN2020118504-appb-000001
右边线函数描述为：
Figure PCTCN2020118504-appb-000002
式中，R为入口模孔直径，即坯料直径；r为出口模孔直径，即棒材直径，L为模腔高度。
在本公开较佳的实施例中，对所述对称流线型挤压模具的模腔中轴线在某一平面进行扭曲变形的步骤还包括：
扭曲后的中轴线Axis的Axis_trig基于三角函数描述为：
Figure PCTCN2020118504-appb-000003
式中，h为扭曲变形的中轴曲线的最大偏移距离；
在本公开较佳的实施例中，对所述对称流线型挤压模具的模腔中轴线在某一平面进行扭曲变形的步骤还包括：
扭曲后的中轴线Axis的Axis_gauss基于类高斯分布函数描述为：
Axis_gauss0＝A exp(-B·z 2)
式中，A，B为待定系数。
在本公开较佳的实施例中，还包括以下步骤：
对Axis_gauss0做数学变形进行修正，其中，先求出Axis_gauss0在端点处的值Axis_gauss0(L/2)，系数A定为h+Axis_gauss0(L/2)，使曲线高度放大Axis_gauss(L/2)倍，再整体减去Axis_gauss0(L/2)得到修正后的基于类高斯分布函数的中轴线Axis_gauss，方程描述为：
Axis_gauss＝(h+Axis_gauss0(L/2))exp(B·z 2)-Axis_gauss0(L/2)
其中，系数B的取值为经验值，B取值为0.01时，曲线端点到原轴线的距离能够控制在0.01mm以内。
在本公开较佳的实施例中，建立变通道转角自弯曲挤压模具的模腔壁面方程包括以下步骤：
模腔壁面描述为曲面方程：
Figure PCTCN2020118504-appb-000004
其中，Axis分别为Axis_trig或Axis_gauss。
本公开提供的一种变通道转角自弯曲挤压模具的制作方法，基于所述的变通道转角自弯曲挤压模具的设计方法进行制作。
本公开提供的一种变通道转角自弯曲挤压模具，通过所述的变通道转角自弯曲挤压模具制作方法制作得到，包括：模具本体；
所述模具本体包括模腔和工作带结构；所述模腔具有自弯曲出口，所述工作带结构沿着所述模腔的自弯曲出口延伸，且所述工作带结构与所述模腔一体连接；
所述模腔的壁面为曲面方程：
Figure PCTCN2020118504-appb-000005
其中，R为模腔的入口模孔直径，即坯料直径；r为模腔的出口模孔直径，即棒材直径，L为模腔高度，Axis为模腔的中轴线的方程。
在本公开较佳的实施例中，所述模腔的中轴线方程基于三角函数描述为：
Figure PCTCN2020118504-appb-000006
式中，h为扭曲变形的中轴曲线的最大偏移距离；
或者，所述模腔的中轴线方程基于类高斯分布函数描述为：Axis_gauss＝(h+Axis_gauss0(L/2))exp(B·z 2)-Axis_gauss0(L/2)
其中，系数B的取值为经验值，B取值为0.01时，曲线端点到原轴线的距离能够控制在0.01mm以内；
其中，Axis分别为Axis_trig或Axis_gauss。
本公开提供的一种基于所述的变通道转角自弯曲挤压模具的挤压方法，包括以下步骤：
将金属容置于所述模具本体的模腔内；
在模腔的入口处控制挤压金属的速度，在模腔的自弯曲出口和工作带结构的限定下，挤压金属形成预设曲率的弯曲型材。
本公开提供的一种变通道转角自弯曲挤压模具设计方法，包括以下步骤：设计基于正弦函数的对称流线型挤压模具，挤压模具模腔的两侧壁面为对称流线型；对所述对称流线型挤压模具的模腔中轴线在某一平面进行扭曲变形，形成一拱形曲线；其中，拱形曲线保持沿挤压方向对称，在曲线的两端无偏移且与轴线相切；根据拱形曲线的中轴线，建立变通道转角自弯曲挤压模具的模腔壁面方程；在变通道转角自弯曲挤压模具的模腔后面增设工作带结构，工作带结构的壁面与挤压方向平行；设计形成变通道转角自弯曲挤压模具；通过金属流经变通道转角自弯曲挤压模具后，利用变通道转角自弯曲挤压模具的模腔，控制挤出速度呈线性分布，从而直接挤压出弯曲件，因此型材不受横向力矩，从而使型材外侧面减小或者杜绝截面变形，而且金属在挤压过程中发生的流动比传统阶梯型挤压模具更 加顺畅，挤压载荷变低；缓解了现有技术中存在的型材弯曲加工时回弹、起皱、截面变形的技术问题和降低挤压时的载荷的技术问题。
附图说明
为了更清楚地说明本公开具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本公开的一些实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本公开实施例提供的变通道转角自弯曲挤压模具的整体结构示意图；
图2为本公开实施例提供的变通道转角自弯曲挤压模具的模具本体的模腔结构示意图；
图3为本公开实施例提供的变通道转角自弯曲挤压模具的挤压形成的型材进行数值计算的结果示意图。
图标：1-模具本体；11-模腔；12-工作带结构；2-模腔几何体；21-对称型挤压模具的中轴线；22-对称型挤压模具的左边轮廓线；23-对称型挤压模具的右边轮廓线；24-变通道转角自弯曲挤压模具的中轴线；25-变通道转角自弯曲挤压模具的左边轮廓线；26-变通道转角自弯曲挤压模具的右边轮廓线；31-挤出的弯曲型材。
具体实施方式
下面将结合实施例对本公开的技术方案进行清楚和完整地描述，显然，所描述的实施例是本公开一部分实施例，而不是全部的实施例。基于本公开中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本公开保护的范围。
需要说明的是，本实施例将型材挤压弯曲一体化成形工艺与流线型挤压模具相结合，提出一种变通道转角自弯曲挤压成形新工艺，通过设计扭曲中轴线的流线型挤压模具结构，使金属在型腔内产生不均匀流动，从而直接挤出弯曲型材。
如图1-图3所示，本实施例提供的一种变通道转角自弯曲挤压模具设计方法，包括以下步骤：设计基于正弦函数的对称流线型挤压模具，所述挤压模具模腔11的两侧壁面为对称流线型；对所述对称流线型挤压模具的模腔11中轴线在某一平面进行扭曲变形，形成一拱形曲线；其中，拱形曲线保持沿挤压方向对称，在曲线的两端无偏移且与轴线相切；根据拱形曲线的中轴线，建立变通道转角自弯曲挤压模具的模腔11壁面方程；在变通道转角 自弯曲挤压模具的模腔11后面增设工作带结构12，工作带结构12的壁面与挤压方向平行。
本实施例提供的一种变通道转角自弯曲挤压模具设计方法，包括以下步骤：设计基于正弦函数的对称流线型挤压模具，挤压模具模腔11的两侧壁面为对称流线型；对所述对称流线型挤压模具的模腔11中轴线在某一平面进行扭曲变形，形成一拱形曲线；其中，拱形曲线保持沿挤压方向对称，在曲线的两端无偏移且与轴线相切；根据拱形曲线的中轴线，建立变通道转角自弯曲挤压模具的模腔11壁面方程；在变通道转角自弯曲挤压模具的模腔11后面增设工作带结构12，工作带结构12的壁面与挤压方向平行；设计形成变通道转角自弯曲挤压模具；通过金属流经变通道转角自弯曲挤压模具后，利用变通道转角自弯曲挤压模具的模腔11，控制挤出速度呈线性分布，从而直接挤压出弯曲件，因此型材不受横向力矩，从而使型材外侧面减小或者杜绝截面变形，而且金属在挤压过程中发生的流动比传统阶梯型挤压模具更加顺畅，挤压载荷变低；缓解了现有技术中存在的型材弯曲加工时回弹、起皱、截面变形的技术问题和降低挤压时的载荷的技术问题。
如图2所示，具体地的设计步骤：在本公开较佳的实施例中，设计基于正弦函数的对称流线型挤压模具的步骤还包括：挤压模具的模腔11沿任意水平截面的形状保持圆形，挤压模具模腔11的边界曲线由正弦函数描述，以对称型挤压模具的中轴线21的中心作为原点，设z方向为挤压方向，对称型挤压模具的左边轮廓线22的函数描述为：
Figure PCTCN2020118504-appb-000007
对称型挤压模具的右边轮廓线23的函数描述为：
Figure PCTCN2020118504-appb-000008
式中，R为入口模孔直径，即坯料直径；r为出口模孔直径，即棒材直径，L为模腔11高度。
在本公开较佳的实施例中，对所述对称流线型挤压模具的模腔11中轴线在某一平面进行扭曲变形的步骤还包括：扭曲后的中轴线Axis的Axis_trig基于三角函数描述为：
Figure PCTCN2020118504-appb-000009
式中，h为扭曲变形的中轴曲线的最大偏移距离。
在本公开较佳的实施例中，对所述对称流线型挤压模具的模腔11中轴线在某一平面进行扭曲变形的步骤还包括：
扭曲后的中轴线Axis的Axis_gauss基于类高斯分布函数描述为：
Axis_gauss0＝A exp(-B·z 2)
式中，A，B为待定系数。
其中，扭曲的中轴线为变通道转角自弯曲挤压模具的中轴线24。
在本公开较佳的实施例中，还包括以下步骤：
对Axis_gauss0做数学变形进行修正，其中，先求出Axis_gauss0在端点处的值Axis_gauss0(L/2)，系数A定为h+Axis_gauss0(L/2)，使曲线高度放大Axis_gauss(L/2)倍，再整体减去Axis_gauss0(L/2)得到修正后的基于类高斯分布函数的中轴线Axis_gauss，方程描述为：
Axis_gauss＝(h+Axis_gauss0(L/2))exp(B·z 2)-Axis_gauss0(L/2)
其中，系数B的取值为经验值，B取值为0.01时，曲线端点到原轴线的距离能够控制在0.01mm以内。
在本公开较佳的实施例中，建立变通道转角自弯曲挤压模具的模腔11壁面方程包括以下步骤：
模腔11壁面描述为曲面方程：
Figure PCTCN2020118504-appb-000010
其中，Axis分别为Axis_trig或Axis_gauss。
如图2所示，本实施例中，通过利用具体数值对上述设计方法的步骤进一步说明：设计模具要生产弯曲棒材直径D＝8mm，因此弯曲棒材的半径r＝4mm，原始坯料选用直径D＝40mm，因此原始坯料的半径R＝20mm，根据需求设定模具高度L＝40mm，根据设计的模具模腔几何体2，其中，对称流线型模腔11的边界曲线由正弦函数描述，以对称型挤压 模具的中轴线21的中心作为原点，设z方向为挤压方向，则对称型挤压模具的左边轮廓线22的函数Line_left描述为：
Figure PCTCN2020118504-appb-000011
对称型挤压模具的右边轮廓线23函数Line_right描述为：
Figure PCTCN2020118504-appb-000012
其中，对称流线型模腔11的壁面方程描述为：
Figure PCTCN2020118504-appb-000013
其中，变通道转角自弯曲挤压模具的中轴线24的最大偏高h＝10mm，三角函数描述的变通道转角自弯曲挤压模具的中轴线24的Axis_trig为：
Figure PCTCN2020118504-appb-000014
另一种基于类高斯分布函数描述的变通道转角自弯曲挤压模具的中轴线24的Axis_gauss描述为：
Axis_gauss＝(10+0.1832)exp(0.01·z 2)-0.1832
变通道转角自弯曲挤压模具的中轴线24的方程Axis确定后，即对称流线型模腔11中轴线扭曲变形后，模腔11结构的其他参数随之做相应的平移，即在变形之前腔体沿某一水平截面的形状保持圆形，在变形之后在于挤压方向垂直的平面上，模腔11壁面各点与变通道转角自弯曲挤压模具的中轴线24的距离相等，即模腔11截面为圆形，只是圆心的位置与原来不同，进而能够确定变通道转角自弯曲挤压模具的左边轮廓线25和变通道转角自弯曲挤压模具的右边轮廓线26形成的变通道转角模腔11壁面的曲面方程；其中，根据变通道转角自弯曲挤压模具结构的构造原理，其中，变通道转角自弯曲挤压模具的中轴线24由Axis_trig建立的变通道转角模腔11壁面的曲面方程为：
Figure PCTCN2020118504-appb-000015
其中，变通道转角自弯曲挤压模具的中轴线24由Axis_gauss建立的变通道转角模腔 11壁面的曲面方程为：
Figure PCTCN2020118504-appb-000016
进一步地，在变通道转角挤压模腔11确定后，在其后增设一定长度的工作带结构12，工作带结构12的长度可以选定为t＝6mm，工作带结构12壁面与挤压方向平行。
本实施例提供的一种变通道转角自弯曲挤压模具的制作方法，基于所述的变通道转角自弯曲挤压模具的设计方法进行制作；本实施例根据上述的设计方法，利用变通道转角模腔11壁面的曲面方程进行机械制作，进而能够制作成变通道转角自弯曲挤压模具。
本实施例提供的一种变通道转角自弯曲挤压模具，通过所述的变通道转角自弯曲挤压模具制作方法制作得到，包括：模具本体1；
模具本体1包括模腔11和工作带结构12；模腔11具有自弯曲出口，工作带结构12沿着模腔11的自弯曲出口延伸，且工作带结构12与所述模腔11一体连接；模腔11的壁面为曲面方程：
Figure PCTCN2020118504-appb-000017
其中，R为模腔11的入口模孔直径，即坯料直径；r为模腔11的出口模孔直径，即棒材直径，L为模腔11高度，Axis为模腔11的中轴线的方程。
在本公开较佳的实施例中，模腔11的中轴线方程基于三角函数描述为：
Figure PCTCN2020118504-appb-000018
式中，h为扭曲变形的中轴曲线的最大偏移距离；
或者，模腔11的中轴线方程基于类高斯分布函数描述为：Axis_gauss＝(h+Axis_gauss0(L/2))exp(B·z 2)-Axis_gauss0(L/2)
其中，系数B的取值为经验值，B取值为0.01时，曲线端点到原轴线的距离能够控制在0.01mm以内；
其中，Axis分别为Axis_trig或Axis_gauss。
本实施例中，增加工作带结构12能够使金属的变形协调性延长，在工作带结构12的通道内减小金属流动速度的差异，使挤出速度的不均匀程度减小，进而弯曲程度变小，因此增加工作带结构12，可以用来设计不同弯曲曲率型材的挤出。
本实施例供的一种基于所述的变通道转角自弯曲挤压模具的挤压方法，包括以下步骤：将金属容置于所述模具本体1的模腔11内；在模腔11的入口处控制挤压金属的速度，在模腔11的自弯曲出口和工作带结构12的限定下，挤压金属形成预设曲率的弯曲型材，从而形成挤出的弯曲型材31。
本实施例中，挤压方法的工艺参数包括，坯料的材料选用AA6063铝合金，挤压比λ＝25，挤压速度v＝10mm/s，坯料预热温度为450℃，挤压筒预热温度为470℃，挤压模具预热温度为480℃，坯料与模具间采用剪切摩擦模型，摩擦因子设置为0.7，坯料与工作带间采用库伦摩擦模型，摩擦因子设为0.3，按照对称性对整个模型的1/2进行模拟，所有组件均划分为四面体单元，坯料网格数30000个，位移步长0.2mm。
如图3所示，对采用本公开实施例的变通道转角自弯曲挤压模具形成的挤出的弯曲型材31进行数值计算，模拟结果的变形体网格示意图，在挤压过程中模腔11出口处的金属流速呈线性分布，型材挤出时会自然的弯向流速较慢的一侧，实现棒型材铝合金的自然弯曲成形，进而一次性挤出有一定弧度的高质量产品，且挤压载荷相对传统模具低。
如图3所示，另外，当金属进入模具后，在同一水平线上越往左应变总是越大，即金属在模具凸起边(左侧边)上的应变大于在模具凹下边(右侧边)的应变，在模具出口处达到最大值，所以左侧的变形总是大于右侧，由于金属的变形协调性，导致挤出型材向右侧方向弯曲。
需要说明的是，本公开所述的“左”、“右”和“z方向”均相对于变通道转角自弯曲挤压模具工作时所述处的位置而言，仅仅为了叙述方便，不应对本公开造成限制。
最后应说明的是：以上各实施例仅用以说明本公开的技术方案，而非对其限制；尽管参照前述各实施例对本公开进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本公开各实施例技术方案的范围。

Claims (10)

  1. 一种变通道转角自弯曲挤压模具设计方法，其特征在于，包括以下步骤：
    设计基于正弦函数的对称流线型挤压模具，所述挤压模具模腔的两侧壁面为对称流线型；
    对所述对称流线型挤压模具的模腔中轴线在某一平面进行扭曲变形，形成一拱形曲线；其中，拱形曲线保持沿挤压方向对称，在曲线的两端无偏移且与轴线相切；
    根据拱形曲线的中轴线，建立变通道转角自弯曲挤压模具的模腔壁面方程；
    在变通道转角自弯曲挤压模具的模腔后面增设工作带结构，工作带结构的壁面与挤压方向平行。
  2. 根据权利要求1所述的变通道转角自弯曲挤压模具设计方法，其特征在于，设计基于正弦函数的对称流线型挤压模具的步骤还包括：
    挤压模具的模腔沿任意水平截面的形状保持圆形，挤压模具模腔的边界曲线由正弦函数描述，以中轴线的中心作为原点，设z方向为挤压方向，左边线函数描述为：
    Figure PCTCN2020118504-appb-100001
    右边线函数描述为：
    Figure PCTCN2020118504-appb-100002
    式中，R为入口模孔直径，即坯料直径；r为出口模孔直径，即棒材直径，L为模腔高度。
  3. 根据权利要求2所述的变通道转角自弯曲挤压模具设计方法，其特征在于，对所述对称流线型挤压模具的模腔中轴线在某一平面进行扭曲变形的步骤还包括：
    扭曲后的中轴线Axis的Axis_trig基于三角函数描述为：
    Figure PCTCN2020118504-appb-100003
    式中，h为扭曲变形的中轴曲线的最大偏移距离。
  4. 根据权利要求2所述的变通道转角自弯曲挤压模具设计方法，其特征在于，对所述对称流线型挤压模具的模腔中轴线在某一平面进行扭曲变形的步骤还包括：
    扭曲后的中轴线Axis的Axis_gauss基于类高斯分布函数描述为：
    Axis_gauss0＝A exp(-B·z 2)
    式中，A，B为待定系数。
  5. 根据权利要求4所述的变通道转角自弯曲挤压模具设计方法，其特征在于，还包括以下步骤：
    对Axis_gauss0做数学变形进行修正，其中，先求出Axis_gauss0在端点处的值Axis_gauss0(L/2)，系数A定为h+Axis_gauss0(L/2)，使曲线高度放大Axis_gauss(L/2)倍，再整体减去Axis_gauss0(L/2)得到修正后的基于类高斯分布函数的中轴线Axis_gauss，方程描述为：
    Axis_gauss＝(h+Axis_gauss0(L/2))exp(B·z 2)-Axis_gauss0(L/2)
    其中，系数B的取值为经验值，B取值为0.01时，曲线端点到原轴线的距离能够控制在0.01mm以内。
  6. 根据权利要求4或5所述的变通道转角自弯曲挤压模具设计方法，其特征在于，建立变通道转角自弯曲挤压模具的模腔壁面方程包括以下步骤：
    模腔壁面描述为曲面方程：
    Figure PCTCN2020118504-appb-100004
    其中，Axis分别为Axis_trig或Axis_gauss。
  7. 一种变通道转角自弯曲挤压模具的制作方法，其特征在于，基于如权利要求1-6任一项所述的变通道转角自弯曲挤压模具的设计方法进行制作。
  8. 一种变通道转角自弯曲挤压模具，通过如权利要求7所述的变通道转角自弯曲挤压模具制作方法制作得到，其特征在于，包括：模具本体；
    所述模具本体包括模腔和工作带结构；所述模腔具有自弯曲出口，所述工作带结构沿着所述模腔的自弯曲出口延伸，且所述工作带结构与所述模腔一体连接；
    所述模腔的壁面为曲面方程：
    Figure PCTCN2020118504-appb-100005
    其中，R为模腔的入口模孔直径，即坯料直径；r为模腔的出口模孔直径，即棒材直径，L为模腔高度，Axis为模腔的中轴线的方程。
  9. 根据权利要求8所述的变通道转角自弯曲挤压模具，其特征在于，所述模腔的中轴线方程基于三角函数描述为：
    Figure PCTCN2020118504-appb-100006
    式中，h为扭曲变形的中轴曲线的最大偏移距离；
    或者，所述模腔的中轴线方程基于类高斯分布函数描述为：Axis_gauss＝(h+Axis_gauss0(L/2))exp(B·z 2)-Axis_gauss0(L/2)
    其中，系数B的取值为经验值，B取值为0.01时，曲线端点到原轴线的距离能够控制在0.01mm以内；
    其中，Axis分别为Axis_trig或Axis_gauss。
  10. 一种基于如权利要求8-9任一项所述的变通道转角自弯曲挤压模具的挤压方法，其特征在于，包括以下步骤：
    将金属容置于所述模具本体的模腔内；
    在模腔的入口处控制挤压金属的速度，在模腔的自弯曲出口和工作带结构的限定下，挤压金属形成预设曲率的弯曲型材。
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