Analysis of Extrusion Law of Large-Scale and Small-Scale Aluminum Profiles with Hollow Thin Wall for Rails

doi:10.12141/j.issn.1000-565X.240397

Abstract

Abstract:

In order to explore the extrusion law of large-scale and small-scale hollow thin-wall aluminum profiles for rails, simulation software HyperXtrude is used to numerically simulate the extrusion process of the profiles, the influences of mold structure and process parameters on the extrusion are analyzed, and the forming rules of two large-scale and small-scale profiles with similar shapes are compared. The results show that, in terms of mold structure, the modification of welding chamber and drainage groove has the most obvious influence on large-scale and small-scale profiles, for instance, the change in welding chamber significantly reduce the maximum deformation of the small-scale profile, with a reduction of 42.82%, while that for the large-scale profile is 25.34%. The change in drainage groove structure shows different impact trends—after altering the drainage groove, the maximum deformation reduction of the large-scale profile is 40.88%, while that of the small-scale profile is 24.72%. The drainage groove of small-scale profile is relatively shorter, and the modification of the drainage groove of large-scale profile is more complicated, so that the change of drainage groove has a more significant impact on large-scale profile. Moreover, in terms of process parameters, according to the changes of metal deformation, metal flow rate and the SDV values of the profile exit section under different conditions, it is found that the extrusion speed and the die temperature have more significant impact on the large-scale profile, while the billet diameter has a more pronounced effect on the small-scale profile. This research provides theoretical support for optimizing the extrusion process of aluminum profiles.

Key words: aluminum profile, extrusion sharping, mold structure, process parameter, numerical simulation

CLC Number:

TG375⁺.41

LIU Guoyong, GAO Shize, ZHU Dongmei. Analysis of Extrusion Law of Large-Scale and Small-Scale Aluminum Profiles with Hollow Thin Wall for Rails[J]. Journal of South China University of Technology(Natural Science Edition), 2025, 53(5): 45-55.

Figures/Tables 17

Fig.1

Fig.2

Fig.3

Fig.4

Fig.5

Table1

Table 2

Performance parameters of 7004 aluminum alloy material"

性能参数	取值		取值
密度/（kg·m^-3）	2 780	杨氏模量/Pa	$4 × 1010$
比热容/（ $J · k g - 1 · K - 1$ ）	875	泊松比	0.35
热导率/（ $W · m - 1 · K - 1$ ）	165

Table 2

Table 3

Performance parameters of H13 die steel material"

性能参数	取值		取值
密度/（kg·m^-3）	7 870	杨氏模量/Pa	$2.1 × 1011$
比热容/（ $J · k g - 1 · K - 1$ ）	460	泊松比	0.35
热导率/（ $W · m - 1 · K - 1$ ）	24.3

Table 3

Table 4

Table 5

Fig.6

Fig.7

Fig.8

Fig.9

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Fig.12

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方案	网格数	网格最小尺寸与特征尺寸之比	最大变形/mm	最大变形误差/%	最高流速/（mm·s^-1）	最大流速误差/%
a	2 751 578	0.300	42.16	0.28	59.55	9.21
b	3 050 509	0.275	42.11	0.17	57.27	5.02
c	3 483 596	0.250	42.02	0.05	54.52	0.02
d	4 169 856	0.225	42.04	0.00	54.54	0.02
e	4 789 498	0.200	42.04	0.00	54.53	0.00
f	5 837 692	0.175	42.04	0.00	54.53	0.00

工艺参数	设定值		设定值
坯料温度/℃	480	挤压速度/（mm·s^-1）	0.6
模具温度/℃	460	坯料直径/mm	640
挤压筒温度/℃	460

边界	接触表面	边界条件类型	参数
边界1	棒料-挤压垫	流入	坯料加热温度：480 ℃；挤压速度：0.6 mm/s
边界2	型材出口	流出	压力：0 MPa；热交换系数：50 W/（m²·K）
边界3	挤出型材内侧面挤出型材外侧面	自由面	型材x、y、z方向牵引力：0 N；法向速度：0 mm/s
边界4	棒料-下模棒料-挤压筒分流孔-下模	实心面	摩擦类型：粘着摩擦；模具与挤压筒温度：460 ℃；热交换系数：3 000 W/（m²·K）
边界5	工作带-模具内侧工作带-模具外侧	工作带	摩擦类型：库伦摩擦；摩擦系数：0.3

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