Study On Substitution Extrusion Technology For Casting Technology Of Explosion-proof Lamp Shell

The topic is for a production task in factory, aimed at designing explosion-proof lamp housing isothermal extrusion process, provide the basis for enterprise process improvement.Explosion proof lamp shell products are widely used in the production of casting process, Die-casing can get very complex product, and can obtain more excellent performance products, but combined with features of the product itself,there are shortcomings can not be ignored:Due to the required high temperature of die-casting, combined with complex structure of explosion-proof lamp shell,the mold temperature hard to export in die casting process, therefore heat can generate severe corrosion on the mold surface, which will impact the life of the die very obvious;At the same time due to the die-casting process itself has some shortcomings, before die-casting forming,the work piece must be putted into melting furnace, which need to add furnace and other equipment, which have no doubt will increase the production costs;After die casting, mold needs to be cooled to a lower temperature, waiting liquid metal to solidify, which is greatly affected the efficiency of production;For now there are more and more serious environmental issues, and die-casting process will emit a lot of smoke in the mass production process, this dust will undoubtedly increase the burden of the environment.For the above proof lamp housing issues owned by the original production process, and in order to further improve the safety performance of explosion-proof lights, this paper put forward a method to replace the original die casting process by using the metal volume forming process. Due to the complexity of the shape of the original die-casting molding shell of anti explosion lamp has high gluten, thin-walled structure and can not be directly used for extrusion technology, this paper will do product structure improvement and optimization of forming process by means of numerical simulation technology. The main research contents and structure of this paper are asfollows:Structure design and optimization. Using general finite element software ANSYS, structural mechanics analysis has been carried out on the explosion-proof lamp shell, getting the stress distribution of 6061 aluminum explosion-proof lamp shell under the pressure which is claimed by GB3836.2-2000, optimizing explosion-proof lamp shell structure and shape size through analysis of the calculation, provided a basis for the process design,compared to the original process,the optimized proof lamp housing extrusion products have lighter weight,and what i did can guide the optimization of some products with similar structure.Designed extrusion technology of lamp shell and optimized the parameters in this process. Simulated the extrusion process of explosion proof lamp shell products by using forming simulation software DEFORM-3D. Analyzed the metal flow in the forming process, and on the basis of which,designed pre-forming parts structure shape; Determined the optimal process plan by the numerical simulation of different process plan;Get the optimal combination of process parameters by the way of different combinations of process parameters as well as multi-objective optimization orthogonal experiment method,which can certify the method of manufacturing explosion-proof lamp housing by the process of extrusion molding is feasible.Die life prediction. Due to Product structure is very complex, in the extrusion process, die surface temperature, surface hardness and material properties have important influence, so in calculating the die wear to consider the influence of factors such as temperature. Therefore, we must use the modified Archard's wear model, using numerical simulation of cavity of each node stress field, velocity field and temperature field calculation of the cavity wear depth, and to predict the service life of the die.