Numerical Simulation On The Forming Process Of Cu/Al Composite Tube And Distribution Of Current Across The Section

A method of using copper-clad aluminum bimetal rod to replace pure copper was developed in this paper, due to the relatively higher cost and shortage resource of copper. The Ansoft-Maxwell2D software was used to analyze the conductance of pure copper rod, get to current distribution through cross-section, and to provide the theoretical knowledgement for replacing pure copper rod from copper-clad aluminum bimetal to. And use the software Deform-3D of large-scale capacity plastic property forming simulation to analyze the forming process of copper- aluminum bimetal by drawing. Through the simulation the drawing parameter was optimized successfully.To begin with, analyze application theory of electromagnetic field, and comprehend the utilization of Maxwell equations set in the numerical analysis of electromagnetic field. And obtain the eddy current field solver, which is fitted for this experiment. Understand the theoretical expression of skin depth .Through the result of numerical analysis, the surface of electric current density is higher than the interior when the current is loaded on pure copper rod. And the higher the frequency of current, the clearer this phenomenon is. The surface of electric current density is no less than three times of that in center, and skin depth is about one millimeter.Furthermore, use the pure copper tube and aluminum rod to process compound by drawing, which external diameter and wall thickness isΦ22mm×1mm. Elastic-plasticity model is used to analyze the workpieces. Optimization program is provided through the simulation results to adjust the processing parameter. And obtain the influence regularities that friction coefficients between inner and outer layer of metal, mould and outer layer of metal affect the composite result remarked by the relative slippage in the procedure of alternation. And the factor level table of orthogonal test is designed for overall analysis. At the same time, the electric conduction property of the composite tube has been numerically calculated to show the distribution of the current density across the section, which has been obtained by changing the size combination of the bimetal tube and the value and frequency of the current. According to the "conductor skin effect", the reasonable wall-thickness of the copper has been found to make the electric conduction property of the bimetal tube most similar to the pure copper bar.The drawing composition process of copper-aluminum bimetal tube has been optimized by adopting the technological parameters above. The experiment materials are T2 pure copper tube and L03 pure aluminum bar, with which the drawing force is measured on the hydraulic universal material testing machine under different conditions. Also the drawing force has been calculated with the upper bound theorem, which is compared with experimental data. The feasibility of simulation result is proved.