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Stress Analysis and Optimum Design of Hot Extrusion Dies

Abstract: A three-dimensional model of a hot extrusion die was developed by using ANSYS software and its second development language—ANSYS parametric design language. A finite element analysis and optimum design were carried out. The three-dimensional stress diagram shows that the stress concentration is rather severe in the bridge of the hot extrusion die, and that the stress distribution is very uneven. The optimum dimensions are obtained. The results show that the optimum height of the extrusion die is 89.596 mm.The optimum radii of diffluence holes are 65.048 mm and 80.065 mm. The stress concentration is reduced by 27%.

Key words: three-dimensional method; modeling; hot extrusion die; optimum design

Introduction

With the continuous improvement of living standards, better thermal conductivity of aluminum alloy profiles. Aluminum components widely used in every aspect of life. Therefore, the aluminum alloy extrusion profiles, profiles of various types of radiators have been widely used in electrical appliances, machinery, and other industries. Variable products and the growing diversity and complexity of high-precision, the extrusion process is the basis for extrusion die. It not only determines the shape, size, accuracy and surface state, but also affect the performance of the product. So extrusion die extrusion technology is the key.

Studies to improve extrusion die quality and prolong its life span usually attempt to simplify 3-D finite element model to 2-D, but it is only right for simple structural shapes. Without a 3-D finite element analysis, the results cannot give practical manufacturing help and offer useful information[3-5]. In this paper, aluminium profile extrusion die was modeled to get in optimum design[6-8].

1 Solid Modeling

Figure 1 shows the male die of a hot extrusion planar combined die. Its external diameter is 227.000 mm, its height is 80.000 mm. Other parameters are shown in Fig. 1. The modeling method is as follows. 1.1 Coordinates of P1 and P5

The coordinates of the point of intersection between the beeline L (y = kx + b) and the circular arc (x2 + y2 =R2) are

1.2 Coordinates of P2 and P6

The coordinates of the intersection point (P2) between beeline L1 (y = kx+b) and

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beeline L2 (y =S1) are

The coordinates of the intersection point (P6) between beeline L3 (y = kx+b) and beeline L4 (y =S1) are

1.3 Coordinates of P3, P4, P7, and P8

P3 and P1 are symmetric about the y-axis. P4 and P2 are also symmetric about the y-axis. P7 and P5 are symmetric about the x-axis. P8 and P6 are also symmetric about the x-axis.

1.4 Variables in the equations

In Eqs. (1)-(6), for points P1 and P2, and R = R1. For points P5 and P6, and R = R2.

R1, R2, T1, T2, S1, and S2 are the change rule along the height (H) of the die expressed as the functions R1=f1 (z), R2=f2 (z), T1=f3 (z), T2=f4 (z), S1=f5 (z), andS2=f6 (z), z

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