外文翻译热挤压模具的优化设计精品.docx

外文翻译热挤压模具的优化设计精品.docx

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外文翻译热挤压模具的优化设计精品

StressAnalysisandOptimumDesignofHotExtrusionDies

Abstract:

Athree-dimensionalmodelofahotextrusiondiewasdevelopedbyusingANSYSsoftwareanditsseconddevelopmentlanguage—ANSYSparametricdesignlanguage.Afiniteelementanalysisandoptimumdesignwerecarriedout.Thethree-dimensionalstressdiagramshowsthatthestressconcentrationisrathersevereinthebridgeofthehotextrusiondie,andthatthestressdistributionisveryuneven.Theoptimumdimensionsareobtained.Theresultsshowthattheoptimumheightoftheextrusiondieis89.596mm.Theoptimumradiiofdiffluenceholesare65.048mmand80.065mm.Thestressconcentrationisreducedby27%.

Keywords:

three-dimensionalmethod;modeling;hotextrusiondie;optimumdesign

Introduction

Withthecontinuousimprovementoflivingstandards,betterthermalconductivityofaluminumalloyprofiles.Aluminumcomponentswidelyusedineveryaspectoflife.Therefore,thealuminumalloyextrusionprofiles,profilesofvarioustypesofradiatorshavebeenwidelyusedinelectricalappliances,machinery,andotherindustries.Variableproductsandthegrowingdiversityandcomplexityofhigh-precision,theextrusionprocessisthebasisforextrusiondie.Itnotonlydeterminestheshape,size,accuracyandsurfacestate,butalsoaffecttheperformanceoftheproduct.Soextrusiondieextrusiontechnologyisthekey.

Studiestoimproveextrusiondiequalityandprolongitslifespanusuallyattempttosimplify3-Dfiniteelementmodelto2-D,butitisonlyrightforsimplestructuralshapes.Withouta3-Dfiniteelementanalysis,theresultscannotgivepracticalmanufacturinghelpandofferusefulinformation[3-5].Inthispaper,aluminiumprofileextrusiondiewasmodeledtogetinoptimumdesign[6-8].

1SolidModeling

Figure1showsthemaledieofahotextrusionplanarcombineddie.Itsexternaldiameteris227.000mm,itsheightis80.000mm.OtherparametersareshowninFig.1.Themodelingmethodisasfollows.

1.1CoordinatesofP1andP5

ThecoordinatesofthepointofintersectionbetweenthebeelineL（y=kx+b）andthecirculararc（x2+y2=R2）are

1.2CoordinatesofP2andP6

Thecoordinatesoftheintersectionpoint（P2）betweenbeelineL1（y=kx+b）andbeelineL2（y=S1）are

Thecoordinatesoftheintersectionpoint（P6）betweenbeelineL3（y=kx+b）andbeelineL4（y=S1）are

1.3CoordinatesofP3,P4,P7,andP8

P3andP1aresymmetricaboutthey-axis.P4andP2arealsosymmetricaboutthey-axis.P7andP5aresymmetricaboutthex-axis.P8andP6arealsosymmetric

aboutthex-axis.

1.4Variablesintheequations

InEqs.

（1）-（6）,forpointsP1andP2,andR=R1.ForpointsP5andP6,andR=R2.

R1,R2,T1,T2,S1,andS2arethechangerulealongtheheight（H）ofthedieexpressedasthefunctionsR1=f1（z）,R2=f2（z）,T1=f3（z）,T2=f4（z）,S1=f5（z）,andS2=f6（z）,z€[0,H].

1.5Sectionshapeatsomeheight

WithlineslinkingP1-P4,P5-P8,withcirculararcfilletingatthepointofintersection（P1-P8）,thesectionshapeatsomeheightisobtained.

1.6Sectionshapeateveryheight

Hisdividedtointerfacialnumber（INUM）equalparts（INUMisdecidedbytheprecision,iftheINUMishigher,theprecisionisbetter）.ThesectionshapeisdrawnateveryheightasshowninFig.2.

1.7Smoothcurvedsurface

UsingSKINcommandinANSYS,smoothcurvedsurfaceswerebuiltalongthelines.Theyarethesurfacesoftheinfluencehole.UsingtheVA（itgeneratesavolumeboundedbyexistingarea）command,asolidwascreatedfromthosesurfaces.

1.8Symmetryofthedie

ThemainbodyandkernelofthedieweredrawnusingtheBooleanoperationsofadd,subtract,etc.（Fig.3）.Thesymmetryofthediewasusedtoacceleratethecomputationsusinga1/4-solidmodelforthefiniteelementanalysis（Fig.4）.

2ComputingModel

Aplanardiethatextrudesthealuminiumalloy（6063Al-Mg-Si）wasusedasanexample.TheliquidoidofAlis657℃[9],andthemelttemperatureofAl+Mg2Siis558℃.Takingtheextrusionpressureandtheproductsqualityintoaccount,theworkingtemperaturewasdeterminedtobe450℃.

Thediematerialis4Cr5MoSiV1（H13）.Belowthe450℃,itsYoungmodulusandPossionratioare210GPaand0.25,respectively.Itsyieldstrengthis1200MPa.Thefrictioncoefficientis0.3.TheSolid923-Dsolidelementwasusedtocarrythroughthefreemesh.Inordertoloadthefrictionalforcewhileextruding,thesurfaceeffectelementSurf154wasusedtoproducetheregularquadrangles（Fig.5）.Forthe1600textruder,theextrusionintensitywascomputedusingEq.（7）[10].ThevaluesareshowninTable1.

Thebridgecollapseoftentakesplaceinthedie.Anditsstrengthisdeterminedbytheheightandthedistributionofthediffluenceholes.Inthispaper,theheight（H）andtheradii（R1andR2）ofthediffl