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Simulation Analysis of Porthole Die Extrusion Process and Die Structure Modifications for an Aluminum Profile with High Length–Width Ratio and Small Cavity

by Zhiwen Liu 1,2,*, Luoxing Li 2,*, Shikang Li 2, Jie Yi 2 and Guan Wang 2
1
School of Mechanical Engineering, University of South China, Hengyang 421001, China
2
State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha 410082, China
*
Authors to whom correspondence should be addressed.
Materials 2018, 11(9), 1517; https://doi.org/10.3390/ma11091517
Received: 26 July 2018 / Revised: 13 August 2018 / Accepted: 20 August 2018 / Published: 23 August 2018
(This article belongs to the Section Manufacturing Processes and Systems)
The design of a porthole die is one of the key technologies for producing aluminum profiles. For an aluminum profile with high length–width ratio and small cavity, it is difficult to control the metal flow through porthole die with the same velocity to ensure the die’s strength. In the present study, the porthole die extrusion process of aluminum profile with small cavity was simulated using HyperXtrude 13.0 software based on ALE formulation. The simulation results show for the traditional design scheme, the metal flow velocity in porthole die at every stage was severely not uniform. The standard deviation of the velocity (SDV) at the die exit was 19.63 mm/s. The maximum displacement in the small mandrel was 0.0925 mm. Then, aiming at achieving a uniform flow velocity and enough die strength, three kinds of die structure modifications for the porthole die were proposed. After optimization, desired optimization results with SDV of 0.448 mm/s at the die exit and small mandrel deflection were obtained. Moreover, the temperature uniformity on the cross-section of die exit, welding pressure, and die strength were improved greatly. Finally, the optimal porthole die was verified by the real extrusion experiment. A design method for porthole die for aluminum with a high length–width ratio and small cavity was proposed, including sunken port bridges to rearrange the welding chamber in upper die, increasing the entrance angle of portholes, introducing the baffle plate, and adjusting the bearing length. View Full-Text
Keywords: aluminum profile; porthole die; small mandrel; ALE formulation; die structure modifications; simulation aluminum profile; porthole die; small mandrel; ALE formulation; die structure modifications; simulation
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MDPI and ACS Style

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.

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