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Analysis and improvement of material flow during extrusion process using spreading pocket die for large-size, flat-wide, and multi-ribs profile

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Abstract

Spreading extrusion is an advanced technology to produce the solid aluminum profiles with large-size, flat-wide, and thin-walled structures. Currently, little research has been reported on the hot extrusion process through spreading pocket die for manufacturing these kinds of aluminum profiles. It is a challenging task for die engineers to control the billet through die cavity with a uniform velocity. Reasonable structure design for spreading pocket die can eliminate extrusion defects and improve the performance of extrudate. In this paper, virtual tryout of spreading extrusion process for a large-size, flat-wide, and multi-ribs aluminum profile was performed through arbitrary Lagrangian-Eulerian simulation. Firstly, spreading pocket die was designed based on the theory of metal plastic flowing. The uniformity of flow velocity distribution on the cross-section of die exit was evaluated quantitatively through standard deviation calculation. Then, a series of structure modifications for the spreading pocket die was proposed to improve material flow during die cavity based on the simulated results. Thirdly, a synthetical comparison of extrusion formability for the modified and initial spreading pocket dies was carried out, including the metal flow behavior, exit temperature, residual stress of extrudate, and peak extrusion force. Finally, the modified extrusion dies were manufactured, and corresponding extrusion experiment was performed to verify the effectiveness and reliability of numerical simulations. The key design points of spreading pocket die for large-size, flat-wide, and multi-ribs aluminum profile were concluded.

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Funding

The authors gratefully acknowledge the research support from the National Natural Science Foundation of China (grant no. 51605234), Hunan Provincial Natural Science Foundation of China (grant no. 2019JJ50510), Scientific Research Fund of Hunan Provincial Education Department (grant no. 18B285), and the Opening Project of Cooperative Innovation Center for Nuclear Fuel Cycle Technology and Equipment, University of South China (grant no. 2019KFY06).

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Authors and Affiliations

  1. College of Mechanical Engineering, University of South China, Hengyang, 421001, China

    Zhiwen Liu

  2. Cooperative Innovation Center for Nuclear Fuel Cycle Technology and Equipment, University of South China, Hengyang, 421001, China

    Zhiwen Liu

  3. State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha, 410082, China

    Luoxing Li & Jie Yi

  4. College of Mechanical Engineering, Ningxia University, Yinchuan, 750021, China

    Guan Wang

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  1. Zhiwen Liu
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  2. Luoxing Li
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  3. Guan Wang
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  4. Jie Yi
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Correspondence to Zhiwen Liu.

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Liu, Z., Li, L., Wang, G. et al. Analysis and improvement of material flow during extrusion process using spreading pocket die for large-size, flat-wide, and multi-ribs profile. Int J Adv Manuf Technol 107, 1115–1129 (2020). https://doi.org/10.1007/s00170-020-04971-1

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  • DOI: https://doi.org/10.1007/s00170-020-04971-1

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