The Calculation Of Flow Velocity And The Design Optimization Of Die Bearing In Aluminium Extrusion Die

Abstract:In the process of aluminum profile extrusion, die land length is an important factor influencing flow velocity. If die land length is rationally designed, material in the die orifice would flow uniformly. The aluminum profile produced can possesses eligible dimensions, and there will be no defects such as distortion and ruffle.In this thesis, extrusion dies with different holes were designed and extrusion process was simulated by finite element software HyperXtrude. The effect of geometry factors such as die hole length, perimeter, profile wall thickness, the distance from the extrusion center and die land length on metal flow velocity has been integrated. The mathematical model of velocity calculation and the general formula of die land length design has been derived.Extrusion dies with Z-shaped, T-shaped, cross, right-angled hole and porthole bridge were designed, and the effects on flow velocity were analyzed.Flow velocity of a flat die and a porthole die was calculated on the basis of the mathematical model. The velocity of the material was adjusted based on the affect of particular die holes. The extrusion process was simulated by HyperXtrude. The simulation results were consistent with the calculation results based on the mathematical model.The bearing length of an aluminum profile extrusion flat die and a porthole die was designed according to the mathematical model. The length was optimized based on the affect of particular die holes. The extrusion process was simulated through HyperXtrude. The results of the simulation showed that the metal flow velocity is homogeneous. The extrusion die is manufactured according to the design drawing. Tooling test was carried out. The profile produced possessed eligible dimensions and there were no distortion or ruffle arisen. The results show that the mathematical model possess reference value for aluminum profile extrusion die design.