Process Simulation And Optimum Design Of Porthole Die For Aluminum Profile Extrusion

For the present,the use of aluminum alloy profile become more and more popular.Extruding method is commonly used in the production, because it can not only save raw material,but also has high productivity.So it is taken into account increasingly.Much work has been done to improve the process .In addition,the pattern of metal flow,stress distribution,strain distribution and stress of die are unclear because the extrusion process is accomplished in a closed chamber. However, die design often depends on the experience and trial-and-error over and over in production. In order to shorten the term and bring down the price, AL6063 alloy profile of circular tube is analyzed. The porthole die are designed by using 3D CAD software SolidWorks2001 and theextrusion are simulated by means of rigid-plastic FEM software Deform-3D.Firstly, design principle of the porthole die is introduced, and the parameters of porthole die structure are calculated. Subsequently, the machine parts are designed including punch,top die, bottom die and the assembly of porthole die by, using SolidWorks2001.Secondly,a three dimensional porthole die extrusion process of a hollow AL6063 alloy profile circular tube is simulated by using the DEFORM-3D software. The correct controlling data are installed and the simulation strategy are applied, for instance, to select the rational time-step, mesh fine, adjust the aberrance element, set right boundary conditions and so on, so the process simulations are carried out successfully.Finally, by the method of orthogonal experiment, the four main factors are selected, which are inside slope angle, outside slope angle,depth of the weld-chamber and the length of bearing. The data are abstracted from the Post-processor of DEFORM-3D as the graph of Load-Stroke, the effective strain of the workpiece, theTmean stress of the weld-chamber and the peak stress of porthole die. The data of simulation are obtained.At last the optimum design of the porthole die are gained by analyzing it. Based on the above, the measures to optimize the design of porthole die are proposed.