Simulation And Experimental Study On Extrusion Forming Rule Of Distorted Channel Self-bending Die

Bending forming technology has become a research hotspot in the field of aluminum alloy profile processing.The surface defects and springback of profiles are easily caused by traditional bending processing methods.These defects can be avoided by self-bending machining methods,and profiles with different curvature radii and reverse bending arcs can be formed in one process by changing extrusion process parameters and die structure parameters.However,it is difficult to accurately control the radius of curvature of the profile and achieve stable and continuous processing of the variable curvature profile.Therefore,the effects of bending deformation rules,extrusion parameters optimization methods,and heat treatment processes on the mechanical properties of aluminum alloy profiles during extrusion have been studied.The optimal extrusion and heat treatment process parameters were obtained.They have important research significance for the precise control of extrusion forming of curved aluminum profiles and the improvement of mechanical properties.In this paper,the extrusion forming rules and heat treatment of 6063 aluminum alloy bending profiles were studied by combining finite element simulation and experimental methods.The stability of the extruded profile arc was verified.The influence of single factor and coupling effects of extrusion process parameters and die structure parameters on the radius of curvature of profiles were summarized.The extrusion methods of variable curvature and reverse arc profiles has been proposed.The multi-objective optimization models were created.The effects of heat treatment processes on the hardness and mechanical properties of 6063 aluminum alloy profiles were analyzed.The specific research results are as follows:Taking the curved plate as an example,extrusion simulation and experiments were conducted based on the existing research foundation for aluminum alloy self-bending extrusion dies.By comparing the obtained profiles,it is found that the simulation and experimental results are relatively consistent,which proves that the laws can be studied through simulation.Further,through the analysis of simulation data,the stability of the profile bending radian was verified.The effects of different processes and structural parameters on the bending and forming of profiles during self-bending extrusion were analyzed.The effects of extrusion speed,billet preheating temperature,friction factor,extrusion ratio,die height,and axis offset on the radius of curvature of profiles were summarized.The extrusion method of variable curvature and reverse arc bending profiles has been proposed,and the feasibility of this method for bending and forming has been verified through finite element simulation.The extrusion process parameters and die structure parameters were optimized through the response surface method combined with CCD experimental design.The curvature radius R of the profile,the maximum temperature T_max of the profile section,and the maximum extrusion force F are the optimization objectives.The extrusion speed v,the preheating temperature T of the billet,the friction factorμ,and the working belt length L are design variables.The extrusion process parameters and the prediction formula for the radius of curvature of the profile are obtained when both the extrusion pressure F and the maximum temperature T_max of the cross-section of the profile are optimized.The accuracy of the response surface prediction model was verified through simulation data.The optimal combination of process parameters for extruding profiles with different radii of curvature was obtained.It provides reference indicators for the selection of actual production parameters.Taking extruded bars as an example,the effects of heat treatment processes on the hardness and mechanical properties of 6063 aluminum alloy profiles were investigated.The changes in comprehensive properties of 6063 aluminum alloy profiles under different solution temperatures and times have been studied in detail.The optimal solution treatment process parameters were obtained.The strengthening mechanism of hardness and mechanical properties was explained.The effects of single-stage aging and double-stage aging time on the hardness and mechanical properties of 6063aluminum alloy profiles were analyzed.The solution aging process under the optimal extrusion parameters was obtained.It provides a sound theoretical basis for the solution aging process of 6063aluminum alloy profiles.