Stress Analysis and Optimum Design of Hot Extrusion Dies.doc
太阳能电动汽车数字仪表盘设计（全套含CAD图纸）
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太阳能
电动汽车
数字
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全套
cad
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STRESSANALYSISANDOPTIMUMDESIGNOFHOTEXTRUSIONDIESABSTRACTATHREEDIMENSIONALMODELOFAHOTEXTRUSIONDIEWASDEVELOPEDBYUSINGANSYSSOFTWAREANDITSSECONDDEVELOPMENTLANGUAGEANSYSPARAMETRICDESIGNLANGUAGEAFINITEELEMENTANALYSISANDOPTIMUMDESIGNWERECARRIEDOUTTHETHREEDIMENSIONALSTRESSDIAGRAMSHOWSTHATTHESTRESSCONCENTRATIONISRATHERSEVEREINTHEBRIDGEOFTHEHOTEXTRUSIONDIE,ANDTHATTHESTRESSDISTRIBUTIONISVERYUNEVENTHEOPTIMUMDIMENSIONSAREOBTAINEDTHERESULTSSHOWTHATTHEOPTIMUMHEIGHTOFTHEEXTRUSIONDIEIS89596MMTHEOPTIMUMRADIIOFDIFFLUENCEHOLESARE65048MMAND80065MMTHESTRESSCONCENTRATIONISREDUCEDBY27KEYWORDSTHREEDIMENSIONALMETHODMODELINGHOTEXTRUSIONDIEOPTIMUMDESIGNINTRODUCTIONWITHTHECONTINUOUSIMPROVEMENTOFLIVINGSTANDARDS,BETTERTHERMALCONDUCTIVITYOFALUMINUMALLOYPROFILESALUMINUMCOMPONENTSWIDELYUSEDINEVERYASPECTOFLIFETHEREFORE,THEALUMINUMALLOYEXTRUSIONPROFILES,PROFILESOFVARIOUSTYPESOFRADIATORSHAVEBEENWIDELYUSEDINELECTRICALAPPLIANCES,MACHINERY,ANDOTHERINDUSTRIESVARIABLEPRODUCTSANDTHEGROWINGDIVERSITYANDCOMPLEXITYOFHIGHPRECISION,THEEXTRUSIONPROCESSISTHEBASISFOREXTRUSIONDIEITNOTONLYDETERMINESTHESHAPE,SIZE,ACCURACYANDSURFACESTATE,BUTALSOAFFECTTHEPERFORMANCEOFTHEPRODUCTSOEXTRUSIONDIEEXTRUSIONTECHNOLOGYISTHEKEYSTUDIESTOIMPROVEEXTRUSIONDIEQUALITYANDPROLONGITSLIFESPANUSUALLYATTEMPTTOSIMPLIFY3DFINITEELEMENTMODELTO2D,BUTITISONLYRIGHTFORSIMPLESTRUCTURALSHAPESWITHOUTA3DFINITEELEMENTANALYSIS,THERESULTSCANNOTGIVEPRACTICALMANUFACTURINGHELPANDOFFERUSEFULINFORMATION35INTHISPAPER,ALUMINIUMPROFILEEXTRUSIONDIEWASMODELEDTOGETINOPTIMUMDESIGN681SOLIDMODELINGFIGURE1SHOWSTHEMALEDIEOFAHOTEXTRUSIONPLANARCOMBINEDDIEITSEXTERNALDIAMETERIS227000MM,ITSHEIGHTIS80000MMOTHERPARAMETERSARESHOWNINFIG1THEMODELINGMETHODISASFOLLOWS11COORDINATESOFP1ANDP5THECOORDINATESOFTHEPOINTOFINTERSECTIONBETWEENTHEBEELINELYKXBANDTHECIRCULARARCX2Y2R2ARE12COORDINATESOFP2ANDP6THECOORDINATESOFTHEINTERSECTIONPOINTP2BETWEENBEELINEL1YKXBANDBEELINEL2YS1ARETHECOORDINATESOFTHEINTERSECTIONPOINTP6BETWEENBEELINEL3YKXBANDBEELINEL4YS1ARE13COORDINATESOFP3,P4,P7,ANDP8P3ANDP1ARESYMMETRICABOUTTHEYAXISP4ANDP2AREALSOSYMMETRICABOUTTHEYAXISP7ANDP5ARESYMMETRICABOUTTHEXAXISP8ANDP6AREALSOSYMMETRICABOUTTHEXAXIS14VARIABLESINTHEEQUATIONSINEQS16,FORPOINTSP1ANDP2,ANDRR1FORPOINTSP5ANDP6,ANDRR2R1,R2,T1,T2,S1,ANDS2ARETHECHANGERULEALONGTHEHEIGHTHOFTHEDIEEXPRESSEDASTHEFUNCTIONSR1F1Z,R2F2Z,T1F3Z,T2F4Z,S1F5Z,ANDS2F6Z,Z0,H15SECTIONSHAPEATSOMEHEIGHTWITHLINESLINKINGP1P4,P5P8,WITHCIRCULARARCFILLETINGATTHEPOINTOFINTERSECTIONP1P8,THESECTIONSHAPEATSOMEHEIGHTISOBTAINED16SECTIONSHAPEATEVERYHEIGHTHISDIVIDEDTOINTERFACIALNUMBERINUMEQUALPARTSINUMISDECIDEDBYTHEPRECISION,IFTHEINUMISHIGHER,THEPRECISIONISBETTERTHESECTIONSHAPEISDRAWNATEVERYHEIGHTASSHOWNINFIG217SMOOTHCURVEDSURFACEUSINGSKINCOMMANDINANSYS,SMOOTHCURVEDSURFACESWEREBUILTALONGTHELINESTHEYARETHESURFACESOFTHEINFLUENCEHOLEUSINGTHEVAITGENERATESAVOLUMEBOUNDEDBYEXISTINGAREACOMMAND,ASOLIDWASCREATEDFROMTHOSESURFACES18SYMMETRYOFTHEDIETHEMAINBODYANDKERNELOFTHEDIEWEREDRAWNUSINGTHEBOOLEANOPERATIONSOFADD,SUBTRACT,ETCFIG3THESYMMETRYOFTHEDIEWASUSEDTOACCELERATETHECOMPUTATIONSUSINGA1/4SOLIDMODELFORTHEFINITEELEMENTANALYSISFIG42COMPUTINGMODELAPLANARDIETHATEXTRUDESTHEALUMINIUMALLOY6063ALMGSIWASUSEDASANEXAMPLETHELIQUIDOIDOFALIS6579,ANDTHEMELTTEMPERATUREOFALMG2SIIS558TAKINGTHEEXTRUSIONPRESSUREANDTHEPRODUCTSQUALITYINTOACCOUNT,THEWORKINGTEMPERATUREWASDETERMINEDTOBE450THEDIEMATERIALIS4CR5MOSIV1H13BELOWTHE450,ITSYOUNGMODULUSANDPOSSIONRATIOARE210GPAAND025,RESPECTIVELYITSYIELDSTRENGTHIS1200MPATHEFRICTIONCOEFFICIENTIS03THESOLID923DSOLIDELEMENTWASUSEDTOCARRYTHROUGHTHEFREEMESHINORDERTOLOADTHEFRICTIONALFORCEWHILEEXTRUDING,THESURFACEEFFECTELEMENTSURF154WASUSEDTOPRODUCETHEREGULARQUADRANGLESFIG5FORTHE1600TEXTRUDER,THEEXTRUSIONINTENSITYWASCOMPUTEDUSINGEQ710THEVALUESARESHOWNINTABLE1THEBRIDGECOLLAPSEOFTENTAKESPLACEINTHEDIEANDITSSTRENGTHISDETERMINEDBYTHEHEIGHTANDTHEDISTRIBUTIONOFTHEDIFFLUENCEHOLESINTHISPAPER,THEHEIGHTHANDTHERADIIR1ANDR2OFTHEDIFFLUENCEHOLESWEREUSEDASDESIGNVARIABLESANDTHEMAXIMUMEQUIVALENTPRESSURESMAXWASUSEDASTHEGOALFUNCTIONTHEDESIGNVARIABLERANGESARELISTEDINTABLE23COMPUTEDRESULTSFIGURE6ISTHEEQUIVALENTSTRESSDIAGRAMFROMFIG6WECANSEETHATTHESTRESSISLARGESTATTHEBRIDGE,ASEXPECTED24MAXIMUMEQUIVALENTSTRESSVALUESARELISTEDINTABLE3FROMLARGETOSMALLTHEDATASHOWSTHATTHENODALMAXIMUMEQUIVALENTSTRESSIS10665MPA,WHICHIS145HIGHERTHANTHESECONDONE9120MPA,ANDTHATTHESTRESSCONVERGENCEISVERYSEVEREINTHEBRIDGE,THISPARTISAPTTOPRODUCECRACKTHEINITIALVALUEOFTHEDESIGNVARIABLESR1,R2,H,Q1,ANDQ2WERE75000MM,88000MM,80000MM,30000,AND30000,RESPECTIVELY,ANDTHEMAXIMUMEQUIVALENTSTRESSSMAX10665MPAINTHE21ITERATIONS,THEOPTIMUMITERATIONWASTHEEIGHTEENTHTHEDESIGNVARIABLEVALUESWERER165048MM,R280065MM,H89596MM,Q130642,Q220045THEMAXIMUMEQUIVALENTSTRESSSMAX7231MPA,WHICHIS27LESSTHEOPTIMUMRESULTSARESHOWNINTABLE44CONCLUSIONS1BASEDONANSYSSOFTWARE,ITSSECONDDEVELOPMENTLANGUAGEAPDLWASUSEDTODEVELOPA3DMODELOFTHEHOTEXTRUSIONDIETHATEXTRUDESALUMINIUMPROFILEHASBEENOBTAINED2THE3DSTRESSDISTRIBUTIONWASVERYUNEVEN,WITHSEVERESTRESSCONCENTRATIONSINTHEBRIDGEOFTHEHOTEXTRUSIONDIETHEOPTIMALGEOMETRICDESIGNHAD27LOWERMAXIMUMSTRESS,ABETTERDIEWILLNOTONLYREDUCEDIENUMBERBUTALSOREDUCETIMELOSTCHANGINGDIES,WHICHWILLGREATLYHEIGHTENPRODUCTIVITY3）DIECANTILEVERDESIGNOFLARGESCALESTREAMINGINTOFALSESTRUCTURENOTONLYISEFFECTIVETOREDUCETHEPRESSUREONTHEMOLDTOTAKEGREATERPOSITIVEDIEASARESULTOFDANGEROUSSECTIONSOFTHEFRACTUREGREATLYEXTENDTHELIFEOFTHEDIE,BUTTHISCANNOTBRINGSTREAMINGBRIDGESTRUCTUREALSOMOREEFFECTIVETOREDUCETHETHICKNESSOFTHEBOTTOMDIEVELOCITY,THEVELOCITYEXTRUDEDENSUREABALANCED,STABLEMEANWHILE,THEST
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