Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity
Abstract
:1. Introduction
2. Porthole Die Design and Simulation Procedures
2.1. Traditional Design Scheme and Geometry Modeling
2.2. Establishment of 3D-FE Model
3. FE Simulation of Traditional Die Design
4. Redesign of Porthole Die
4.1. First Step: Rearranging the Welding Chamber in Upper Die
4.2. Second Step: Introducing the Baffle Plates
4.3. Third Step: Adjusting the Die Bearings
5. Comparison between the Initial and Optimal Porthole Dies
5.1. Metal Flow Pattern
5.2. Welding Pressure
5.3. Temperature Distribution
5.4. Extrusion Load
5.5. Die Displacement
6. Experimental Verification
7. Conclusions
- The metal flow behavior in the porthole die at different stages of extrusion process for the initial die scheme is severely not uniform. The SDV at the die exit is 19.63 mm/s. The maximum displacement in the upper die and mandrel are 0.107 and 0.0925 mm, respectively.
- By three steps of die structure modifications, the SDV at the die exit is reduced to 0.448 mm/s. The distortion of the profile is avoided effectively. The mean welding pressure in the welding zones for the optimal die is 197.3 MPa, being 331.72% higher than that of the initial die. The maximum temperature of extrudate at the die exit for the optimal die is 539.3 °C, being 8.6 °C higher than that of the initial die. The maximum displacement in the upper die is decreased from 0.107 to 0.0656 mm, and the mandrel deflection is decreased from 0.0925 to 0.04648 mm.
- The good agreement between the simulation and experimental results shows the modification strategy of porthole die based ALE formulation is practicable and it can provide theoretical guidance for porthole die design of any other similar profiles.
- A design route of porthole die for aluminum profile with a small mandrel is proposed, including sunken port bridges to design the welding chamber in the upper die, increasing the inlet angle of portholes, adding the baffle plates, and adjusting the die bearings.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Physical Properties | AA6063 Aluminum Alloy | AISI H13 Steel |
---|---|---|
Density (Kg/m3) | 2700 | 7870 |
Young’s modulus (MPa) | 68,900 | 210,000 |
Poisson’s ratio | 0.3 | 0.33 |
Thermal conductivity (W/(m·K)) | 198 | 24.3 |
Specific heat (J/(kg·K)) | 900 | 460 |
Thermal expansion coefficient (1/K) | 1.0 × 10–5 | - |
Conditions | Values |
---|---|
Billet diameter (mm) | 210 |
Billet length (mm) | 350 |
Extrusion ratio | 75.8 |
Extrusion speed (mm/s) | 2 |
Billet temperature (°C) | 480 |
Container and die temperature (°C) | 430 |
Friction coefficient at billet/container and die | Sticking |
Friction coefficient at billet/die bearing | 0.3 |
Heat thermal coefficient between billet/container and die (W/(m2·°C)) | 3000 |
Design Schemes of Baffle Plates | Case 1 | Case 2 | Case 3 | Case 4 |
---|---|---|---|---|
Length of d (mm) | 55 | 57.5 | 60 | 65 |
Max. velocity (mm/s) | 217.8 | 157.7 | 162.8 | 168.8 |
Min. velocity (mm/s) | 141.2 | 149.9 | 149.8 | 140.8 |
SDV | 16.266 | 1.892 | 3.656 | 8.825 |
Displacement of profiles (mm) | 6.657 | 0.927 | 1.499 | 3.318 |
Position | l1 | l2 | l3 | l4 | l5 |
---|---|---|---|---|---|
Initial design (mm) | 2 | 4 | 6.4 | 4.3 | 2.8 |
Optimal design (mm) | 2.75 | 4.06 | 6.35 | 4.18 | 3.32 |
Design Schemes | Initial Design | Modification Scheme 1 | Modification Scheme 2 | Modification Scheme 3 |
---|---|---|---|---|
Extrusion load (KN) | 10,617.3 | 10,140.6 | 13,718.4 | 13,903.2 |
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Liu, Z.; Li, L.; Li, S.; Yi, J.; Wang, G. Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity. Materials 2018, 11, 1517. https://doi.org/10.3390/ma11091517
Liu Z, Li L, Li S, Yi J, Wang G. Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity. Materials. 2018; 11(9):1517. https://doi.org/10.3390/ma11091517
Chicago/Turabian StyleLiu, Zhiwen, Luoxing Li, Shikang Li, Jie Yi, and Guan Wang. 2018. "Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity" Materials 11, no. 9: 1517. https://doi.org/10.3390/ma11091517