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Investigation on Effects of Die Orifice Layout on Three-Hole Porthole Extrusion of Aluminum Alloy 6063 Tubes

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Abstract

Currently, with the increasing demand of high production output, much attention is paid to the research and development of multi-hole extrusion die. However, owing to the complexity of multi-hole porthole extrusion technology, it has not been applied widely in practice for the production of aluminum profiles, especially for porthole die with an odd number of die orifices. The purpose of this study is to design a three-hole porthole die for producing an aluminum tube and to optimize the location of die orifices based on computer-aided design and engineering. First, three-hole extrusion dies for different locations of die orifices are designed. Then, extrusion processes with different multi-hole porthole dies are simulated by means of HyperXtrude. Through numerical simulation, metal flow, temperature distribution, welding pressure, extrusion load, and die stress, etc. could be obtained, and the effects of the location of die orifices on extrusion process are investigated. With the increasing distance between die orifice and extrusion center (described as eccentricity ratio), metal flow becomes nonhomogeneous, and twisting or bending deformation of profile occurs, but the welding pressure rises, which improves the welding quality of profiles. However, the required extrusion force, billet and die temperature, die displacement, and stress induce no significant changes. In comparison with the extrusion force during single-hole porthole extrusion, there is 18.5% decrease of extrusion force during three-hole porthole extrusion. Finally, design rules for this kind of multi-hole extrusion dies are summarized.

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Acknowledgments

The authors would like to acknowledge the financial supports from the National Natural Science Foundation of China (51105230); the State Key Laboratory of Materials Processing and Die & Mould Technology (2011-P09), Program for Changjiang Scholars and Innovative Research Team in University of Ministry of Education of China (IRT0931); and the National Science & Technology Pillar Program in the Eleventh Five-year Plan Period of the People’s Republic of China (2009BAG12A07-B01).

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Authors and Affiliations

  1. Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, 250061, Shandong, People’s Republic of China

    Cunsheng Zhang, Guoqun Zhao, Hao Chen, Yanjin Guan & Haijin Cai

  2. State Key Laboratory of Materials Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan, 430074, Hubei, People’s Republic of China

    Cunsheng Zhang

  3. CSR Qingdao Sifang Co., Ltd, Qingdao, 266111, Shandong, People’s Republic of China

    Baojie Gao

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  1. Cunsheng Zhang
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  2. Guoqun Zhao
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  3. Hao Chen
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Correspondence to Guoqun Zhao.

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Zhang, C., Zhao, G., Chen, H. et al. Investigation on Effects of Die Orifice Layout on Three-Hole Porthole Extrusion of Aluminum Alloy 6063 Tubes. J. of Materi Eng and Perform 22, 1223–1232 (2013). https://doi.org/10.1007/s11665-012-0405-y

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  • DOI: https://doi.org/10.1007/s11665-012-0405-y

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