Structural Optimization Of Aluminum Extrusion Porthole Die And Design Of Supporting Cutter

Aluminum profiles are widely used in all walks of life because of their excellent characteristics.Aluminum profile has developed from simple and miniaturized section to complex and large section.Nowadays,the production method of empirical die design and repeated debugging extrusion parameter setting after many die tests and repairs can not meet the production needs of modern aluminum profiles.In this paper,the extrusion process of aluminum profile is analyzed by numerical simulation technology,and then the die structure is optimized and the extrusion parameters are adjusted,which provides some guidance for the design of aluminum profile extrusion die and the setting of extrusion parameters,which is of great significance for enterprises to reduce production costs and improve product quality and production efficiency.The research contents are as follows:(1)Compare the accuracy of the two software in simulating the extrusion process.HyperXtrue software has no problems such as mesh distortion and mesh redivision,and the calculation results of stress and die displacement are more in line with the reality.(2)The effects of arch bridge die surface and sinking bridge structure of shunt bridge on aluminum profile extrusion process were studied.The numerical simulation results show that the arch bridge die surface can improve the overall stress distribution of the die;The sinking bridge structure of the diversion bridge can make the stress distribution on the diversion bridge more reasonable;The arch bridge formwork surface and the diversion bridge sinking bridge are the best structures,which can reduce the maximum stress at the junction of the formwork core and the diversion bridge by about18.2% and 15%,respectively,and then reduce the risk of early failure of the mould due to the fracture at the junction.(3)The effects of the depth of the shunting hole and the width of the shunting bridge on the extrusion process of aluminum profile were studied.With the increase of the depth of the shunt hole,the maximum stress at the junction of the mold core and the shunt bridge can be reduced by about 19.5%;With the increase of the depth of the diversion hole and the width of the diversion bridge,the displacement at the mold core can be reduced by about 45% and 10%.(4)In order to improve the die stiffness,the topology optimization of the splitter bridge part of the split combined extrusion die is carried out.Taking the die core displacement as the index,the die stiffness is increased by 30%.The topology results of the die show that the material density at the inner side of the flow bridge on the die surface is significantly higher than that at the outer side,which is similar to the arch bridge die in structure.(5)Explore the influence of single parameter change of "three temperatures and one speed" on extrusion molding;Using the orthogonal experimental method and taking the SDV and SDT of extruded profile as parameter indexes,the optimal extrusion parameter schemes are explored as follows: extrusion speed 2mm / s,blank preheating temperature 500 ?,die preheating temperature 500 ?,extrusion barrel preheating temperature 440 ?;The extrusion speed is 2mm / s,the billet preheating temperature is 480 ?,the die preheating temperature is 480 ?,and the extrusion barrel preheating temperature is 450 ?.(6)New cutting tools and cutting methods are designed for the arch bridge die surface: rotary cutting and multi tool profiling cutting.