Numerical simulation study of effect of die structure on the extrusion deformation of FGH4096 alloys
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摘要: 采用有限元数值模拟软件与正交试验相结合的方法研究了FGH4096合金包覆热挤压过程，系统分析了模具模角、入口圆角半径和工作带长度对挤压制品有效应变分布、温度分布和挤压载荷的影响。结果表明：模角越大，有效应变分布均匀区域减少，挤压载荷升高，挤压过程中产生的温升效应严重；模角越小，有利于挤压载荷的降低，挤压制品心部温升效应减轻，但心部出现有效应变小于1.500的区域增大。入口圆角半径和工作带长度对挤压制品的有效应变分布、温度分布和挤压载荷影响不大。当模角为45°时，有效应变分布均匀的区域增大，有效应变分布更为均匀。制作挤压模具进行模拟实验验证，结果表明实际挤压过程和数值模拟的数据相吻合，证明模拟参数设置合理，对实际生产具有指导意义。Abstract: A combination of finite element numerical simulation software and orthogonal experiment was used to study the hot extrusion process of FGH4096 alloys. The influence of die angle, entrance fillet radius, and working belt length on the effective strain distribution, temperature distribution, and extrusion load of the extruded products was systematically analyzed. The results show that, with the increase of the die angle, the effective strain distribution area decreases, the extrusion load increases, and the temperature rise effect is serious in the extrusion process. The smaller the die angle, the lower the extrusion load, and the effect of temperature rise in the core of the extruded products is reduced, but the area of effective strain less than 1.500 in the core increases. The radius of the inlet fillet and the length of the working belt have little effect on the effective strain distribution, temperature distribution, and extrusion load in the extruded product. When the die angle is 45°, the area with the uniform effective strain distribution increases and the effective strain distribution becomes more uniform. The extrusion die was made for the simulation experiment verification. In the result, the actual extrusion process and the numerical simulation data are consistent, proving that the simulation parameters are set reasonably, which has the guiding significance for the practical production.
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Key words:
- finite element numerical simulation /
- FGH4096 /
- effective strain /
- hot extrusion /
- die
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图 2 不同实验过程中制品内有效应变分布云图：（a）1#；（b）2#；（c）3#；（d）4#；（e）5#；（f）6#；（g）7#；（h）8#；（i）9#
Figure 2. Effective strain distribution of the extrusion billets: (a) 1#; (b) 2#; (c) 3#; (d) 4#; (e) 5#; (f) 6#; (g) 7#; (h) 8#; (i) 9#
图 3 挤压过程中挤压载荷行程曲线：（a）1#；（b）2#；（c）3#；（d）4#；（e）5#；（f）6#；（g）7#；（h）8#；（i）9#
Figure 3. Load curve of the extrusion process: (a) 1#; (b) 2#; (c) 3#; (d) 4#; (e) 5#; (f) 6#; (g) 7#; (h) 8#; (i) 9#
图 4 挤压制品内温度分布：（a）1#；（b）2#；（c）3#；（d）4#；（e）5#；（f）6#；（g）7#；（h）8#；（i）9#
Figure 4. Temperature distribution of the extrusion billets: (a) 1#; (b) 2#; (c) 3#; (d) 4#; (e) 5#; (f) 6#; (g) 7#; (h) 8#; (i) 9#
图 6 挤压制品显微组织形貌：（a）心部；（b）1/2R；（c）边缘
Figure 6. Microstructure of the extrusion billets: (a) core; (b) 1/2R; (c) edge
图 7 挤压制品挤压前（热等静压态）组织示意图
Figure 7. Microstructure of the extrusion billet before extrusion
图 8 挤压载荷随挤压时间变化曲线：（a）模拟结果；（b）实验结果
Figure 8. Extrusion load curves with the extrusion time: (a) simulation result; (b) experiment result
表 1 因素水平表
Table 1. Factors level table
因素 模角 / (°) 工作带长度 / mm 入口圆角半径 / mm 水平 1 60 25 10 2 45 30 15 3 30 35 20 
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表 2 正交实验表
Table 2. Orthogonal table
实验编号 模角 / (°) 工作带长度 / mm 入口圆角半径 / mm 1# 60 25 10 2# 60 30 15 3# 60 35 20 4# 45 25 15 5# 45 30 20 6# 45 35 10 7# 30 25 20 8# 30 30 10 9# 30 35 15
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