Complex thin-wall hollow aluminum profile mold design method and related equipment

Abstract

The invention discloses a complex thin-wall hollow aluminum profile mold design method and related equipment, and relates to the field of metal processing.The method comprises the steps that initial mold shape parameter information is determined based on main shape parameter information of a target profile; performing an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result; based on the initial mold simulation result, the section outlet speed mean square error is calculated; and under the condition that the outlet speed mean square error is greater than a preset mean square error, carrying out structure optimization design operation on the initial mold shape, so that the outlet speed mean square error is smaller than or equal to the preset mean square error, and obtaining a corresponding target mold.

Description

Technical Field

[0001] The present invention relates to the field of metal processing, and more specifically, to a complex thin-walled hollow aluminum profile mold design method and related equipment. Background Art

[0002] During the extrusion molding process, mold design is a key factor in ensuring the quality of profiles. Traditional mold design is mostly based on the designer's experience or industry standards, and the mold shape of complex profiles is initially designed and directly used in production. However, for profiles with complex shapes, large cross-sectional variations, or multi-cavity structures, this experience-based design method often makes it difficult to ensure uniform flow of materials in the mold, which can easily lead to quality problems such as uneven flow rate, stress concentration, and deformation during profile extrusion. Especially for high-demand profile production, such as aerospace, automotive industry, etc., the product's dimensional accuracy and material performance requirements are more stringent, and traditional mold design methods cannot effectively meet these requirements.

[0003] In order to solve the above problems, the existing technology has introduced finite element simulation technology. By simulating the extrusion process, the flow behavior of the material can be predicted and the mold design can be optimized. However, the existing simulation optimization methods often only optimize a single factor (such as a local feature inside the mold), lacking global consideration of the overall structure, resulting in the simulation optimization results being unable to effectively improve the overall molding effect of the mold. In addition, when optimizing the design, the existing simulation methods mostly rely on manual adjustments by the designer, which is inefficient and has a long optimization cycle. Summary of the invention

[0004] A series of simplified concepts are introduced in the Summary of the Invention section, which will be further described in detail in the Detailed Description of the Invention section. The Summary of the Invention section of this application does not mean to attempt to define the key features and essential technical features of the claimed technical solution, nor does it mean to attempt to determine the scope of protection of the claimed technical solution.

[0005] In the first aspect, the present application proposes a complex thin-walled hollow aluminum profile mold design method, comprising:

[0006] Determine initial mold shape parameter information based on main shape parameter information of target profile;

[0007] Performing an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result;

[0008] Calculate the mean square deviation of the profile exit velocity based on the above initial die simulation results;

[0009] When the mean square error of the outlet velocity is greater than the preset mean square error, a structural optimization design operation is performed on the initial mold shape to make the mean square error of the outlet velocity less than or equal to the preset mean square error, and a corresponding target mold is obtained.

[0010] In a feasible implementation manner, the initial mold finite element simulation operation is performed based on the initial mold shape parameter information to obtain the initial mold simulation result, including:

[0011] Based on the initial mold shape parameter information, a three-dimensional model of a diversion assembly mold is constructed, wherein the diversion assembly mold includes a diversion chamber, a welding chamber, a mold core and a working belt;

[0012] Based on the above three-dimensional model, a finite element model is established, and extrusion parameters and boundary conditions are set, and an initial mold finite element simulation operation is performed to obtain an initial mold simulation result.

[0013] In a feasible implementation, the above-mentioned three-dimensional model is constructed based on any one of the three-dimensional software such as UG, SolidWorks and Pro / e, the above-mentioned finite element simulation operation is performed based on any one of the simulation software such as HyperXtrude, Abaqus and Ansys, and the above-mentioned target mold includes a diversion mold.

[0014] In a feasible implementation manner, calculating the mean square error of the profile exit velocity based on the initial mold simulation results includes:

[0015] The mean square deviation of the exit velocity SDV is calculated based on the following formula:

[0016]

[0017] In the formula, v i is the flow velocity at the i node on the investigated section; v is the average velocity of all investigated nodes; n is the total number of investigated nodes.

[0018] In a feasible implementation, the flow velocity V at the above node is calculated based on the following formula: i :

[0019] V i =m×A i +n×T i +p×R i +q×H i +ξ

[0020] In the formula, A i is the shape factor of the die hole, T i is the temperature of the material to be extruded, L i is the die hole length, R i H is the distance between the die hole and the center of the die,i is the length of the local working zone of the die hole, m, n, p, q are the influencing factors corresponding to each parameter, ξ is a constant determined by other factors in the extrusion process. For the same set of molds, ξ is the same, and for different molds, ξ is different.

[0021] In a feasible implementation, the above-mentioned influencing factor is determined based on the following formula:

[0022] m=-157.2+27.205λ

[0023] n=7.42+0.0142λ 2.45

[0024] p=-0.489+0.456e -λ / 6.676

[0025] q=-0.837-1.671λ

[0026] Where λ is the extrusion ratio.

[0027] In a feasible implementation manner, the above structural optimization design operation includes one or more of increasing the size and height of the blocking block, increasing the length of the working belt, and increasing the volume of the intermediate diversion hole.

[0028] In the second aspect, the present application proposes a complex thin-walled hollow aluminum profile mold design device, comprising:

[0029] A determination unit, used to determine initial mold shape parameter information based on main shape parameter information of the target profile;

[0030] An acquisition unit, used for performing an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result;

[0031] A calculation unit, used for calculating the mean square error of the profile outlet velocity based on the initial die simulation result;

[0032] The optimization unit is used to perform a structural optimization design operation on the initial mold shape when the outlet velocity mean square deviation is greater than a preset mean square deviation, so that the outlet velocity mean square deviation is less than or equal to the preset mean square deviation, and obtain a corresponding target mold.

[0033] In a third aspect, an electronic device comprises: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor is used to implement the steps of the complex thin-walled hollow aluminum profile mold design method as described in any one of the first aspects above when executing the computer program stored in the memory.

[0034] In a fourth aspect, the present application further proposes a computer-readable storage medium having a computer program stored thereon, and when the computer program is executed by a processor, the complex thin-walled hollow aluminum profile mold design method of any one of the first aspects is implemented.

[0035] In summary, the present application provides a mold design optimization method based on the mean square deviation of the outlet velocity by combining finite element simulation with the optimization design of the mold structure. Compared with the traditional design method that relies on experience, the present application determines the initial mold shape by the shape parameters of the profile, and uses finite element simulation to perform data-driven analysis on the design of the mold. By analyzing the simulation results, especially calculating the mean square deviation of the profile outlet velocity, the flow of the material in the mold can be quantified. This data-based optimization design method can significantly improve the accuracy of mold design and effectively reduce the blindness and uncertainty in the design. This method quickly obtains the velocity distribution of the profile at the mold outlet by performing finite element simulation on the initial mold shape. If the simulation results show that the mean square deviation of the outlet velocity is greater than the preset threshold, the problem in the mold design can be directly identified and the structure can be quickly optimized. This combination of simulation and optimization avoids the trial and error process in traditional design and greatly shortens the design cycle. The present application not only focuses on the optimization of local areas, but also optimizes the overall design of the mold through the global indicator of the mean square deviation of the outlet velocity. Through this optimization process, the profile can be guaranteed to flow more evenly throughout the mold, thereby reducing defects in the molding process, such as material accumulation, flow dead zones, and excessive local stress, and ensuring the profile dimensional accuracy and surface quality. Through automated simulation analysis and optimization algorithms, the present application scheme can perform multiple iterations of mold optimization without too much manual intervention. This combination of automated simulation and optimization significantly improves the efficiency of mold design, reduces the errors and uncertainties caused by reliance on manual experience, and is particularly suitable for mold design requirements for complex profiles and multi-cavity structures. By controlling the uniformity of the profile outlet velocity, this solution can significantly reduce the deformation and dimensional instability of the profile during the extrusion process, thereby improving the product yield. At the same time, due to the more uniform flow of the material, the mechanical properties and surface quality of the profile are also improved, ensuring the consistency and high quality of the product. By combining the shape information of the profile with finite element simulation analysis, the present application uses the mean square error of the outlet velocity as the optimization basis, which can accurately identify problems in mold design and perform global structural optimization. Compared with traditional technologies, this solution has significant advantages in design accuracy, optimization efficiency and material flow control. It can effectively improve the extrusion molding quality and consistency of complex profiles, and provide a more intelligent and efficient solution for mold design. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present specification. Also, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings:

[0037] Figure 1 A schematic diagram of the process of designing a complex thin-walled hollow aluminum profile mold provided in an embodiment of the present application;

[0038] Figure 2 A schematic cross-sectional view of a target profile provided in an embodiment of the present application;

[0039] Figure 3 A structural schematic diagram of a first component of an initial mold provided in an embodiment of the present application;

[0040] Figure 4 A structural schematic diagram of a second component of an initial mold provided in an embodiment of the present application;

[0041] Figure 5 A schematic diagram of a simulation model provided in an embodiment of the present application;

[0042] Figure 6 A schematic diagram of simulation results corresponding to an initial mold provided in an embodiment of the present application;

[0043] Figure 7 A structural schematic diagram of a first component of a modified mold provided in an embodiment of the present application;

[0044] Figure 8 A structural schematic diagram of a second component of a modified mold provided in an embodiment of the present application;

[0045] Fig. 9 A schematic diagram of simulation results corresponding to a modified mold provided in an embodiment of the present application;

[0046] Fig.10 A schematic diagram of the structure of a complex thin-walled hollow aluminum profile mold design device provided in an embodiment of the present application;

[0047] Fig.11 A schematic diagram of the structure of an electronic device designed for a complex thin-walled hollow aluminum profile mold provided in an embodiment of the present application. DETAILED DESCRIPTION

[0048] The terms "first", "second", "third", "fourth", etc. (if any) in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable where appropriate, so that the embodiments described herein can be implemented in an order other than that illustrated or described herein. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices. The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments.

[0049] In some related technologies, the aluminum extrusion process is analyzed based on the plastic forming theory. The parameters such as the billet size, the internal cavity size of the mold, the extrusion deformation force, the metal flow rate, the friction coefficient, etc. are used for calculation according to the corresponding calculation formula. The upper limit element method and the variational upper limit method are mainly used in the analysis of the aluminum extrusion process. Among them, the upper limit element method is simple and feasible, can calculate the extrusion force quickly, and is widely used. However, this method cannot analyze the stress and strain fields.

[0050] Other related technologies use experiments to study the aluminum extrusion process, analyze the aluminum extrusion process based on experimental data, and design aluminum extrusion dies and processes. The experimental results are true and reliable, and are often used to determine certain specific surfaces and local stresses. This method has high investment costs and a long cycle, and it is difficult to meet the needs of actual research.

[0051] See also Figure 1 , which is a schematic diagram of the process of designing a complex thin-walled hollow aluminum profile mold provided by an embodiment of the present application, and may specifically include:

[0052] S110, determining initial mold shape parameter information based on main shape parameter information of the target profile;

[0053] For example, Figure 2 The cross-sectional shape of a profile is shown. The shape parameter information of the initial mold can be determined based on the size and shape information of the profile. The initial mold is a mold determined based on the cross-sectional shape of the profile and design experience or other standards. This step is mainly determined based on existing design experience, industry standards or existing design data. Usually, the mold is preliminarily designed based on the appearance, thickness, cavity structure and other characteristics of the profile as the basis for subsequent simulation analysis.

[0054] S120, performing an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result;

[0055] For example, the initial die is simulated using a finite element analysis tool to simulate the material flow, stress distribution, temperature change, etc. of the profile during the extrusion process. The simulation analysis simulates the behavior of the material during the extrusion process, including the flow of the material in the die and the velocity distribution at the outlet. The simulation results are used to evaluate the rationality of the initial die design and identify possible design problems, such as uneven material flow and stress concentration.

[0056] S130, calculating the mean square error of the profile outlet velocity based on the initial mold simulation result;

[0057] For example, based on the simulation results, the mean square deviation of the velocity of the profile at the die outlet is calculated. The mean square deviation of the outlet velocity is an important indicator to measure whether the material flows evenly in the die. The larger the mean square deviation, the uneven flow of the material in the die, which may cause deformation of the profile, unstable dimensions or quality problems. Through this calculation, it is possible to intuitively determine whether the die design is reasonable and whether it needs further optimization.

[0058] S140. When the mean square error of the outlet velocity is greater than a preset mean square error, a structural optimization design operation is performed on the initial mold shape to make the mean square error of the outlet velocity less than or equal to the preset mean square error, and a corresponding target mold is obtained.

[0059] When the calculated mean square error of the outlet velocity is greater than the preset threshold, it indicates that there is a problem with the structure of the initial mold design and the material flow is not uniform. According to the simulation analysis results, the mold shape is adjusted by using the structural optimization method. For example, the size and position of the diversion holes can be optimized, and the flow channel design of the mold can be adjusted to improve the flow characteristics of the material. The goal of structural optimization is to make the material flow at the outlet more uniform, and ultimately make the mean square error of the outlet velocity less than or equal to the preset threshold.

[0060] After multiple structural optimization designs and simulation analyses, we finally obtained a target die that met the requirements, that is, the mean square deviation of the outlet velocity reached the expected standard, ensuring the extrusion quality and consistency of the profile.

[0061] In summary, the present application provides a mold design optimization method based on the mean square deviation of the outlet velocity by combining finite element simulation with the optimization design of the mold structure. Compared with the traditional design method that relies on experience, the present application determines the initial mold shape by the shape parameters of the profile, and uses finite element simulation to perform data-driven analysis on the design of the mold. By analyzing the simulation results, especially calculating the mean square deviation of the profile outlet velocity, the flow of the material in the mold can be quantified. This data-based optimization design method can significantly improve the accuracy of mold design and effectively reduce the blindness and uncertainty in the design. This method quickly obtains the velocity distribution of the profile at the mold outlet by performing finite element simulation on the initial mold shape. If the simulation results show that the mean square deviation of the outlet velocity is greater than the preset threshold, the problem in the mold design can be directly identified and the structure can be quickly optimized. This combination of simulation and optimization avoids the trial and error process in traditional design and greatly shortens the design cycle. The present application not only focuses on the optimization of local areas, but also optimizes the overall design of the mold through the global indicator of the mean square deviation of the outlet velocity. Through this optimization process, the profile can be guaranteed to flow more evenly throughout the mold, thereby reducing defects in the molding process, such as material accumulation, flow dead zones, and excessive local stress, and ensuring the profile dimensional accuracy and surface quality. Through automated simulation analysis and optimization algorithms, the present application scheme can perform multiple iterations of mold optimization without too much manual intervention. This combination of automated simulation and optimization significantly improves the efficiency of mold design, reduces the errors and uncertainties caused by reliance on manual experience, and is particularly suitable for mold design requirements for complex profiles and multi-cavity structures. By controlling the uniformity of the profile outlet velocity, this solution can significantly reduce the deformation and dimensional instability of the profile during the extrusion process, thereby improving the product yield. At the same time, due to the more uniform flow of the material, the mechanical properties and surface quality of the profile are also improved, ensuring the consistency and high quality of the product. By combining the shape information of the profile with finite element simulation analysis, the present application uses the mean square error of the outlet velocity as the optimization basis, which can accurately identify problems in mold design and perform global structural optimization. Compared with traditional technologies, this solution has significant advantages in design accuracy, optimization efficiency and material flow control. It can effectively improve the extrusion molding quality and consistency of complex profiles, and provide a more intelligent and efficient solution for mold design.

[0062] In some examples, the initial mold finite element simulation operation is performed based on the initial mold shape parameter information to obtain an initial mold simulation result, including:

[0063] Based on the initial mold shape parameter information, a three-dimensional model of a diversion assembly mold is constructed, wherein the diversion assembly mold includes a diversion chamber, a welding chamber, a mold core and a working belt;

[0064] Based on the above three-dimensional model, a finite element model is established, and extrusion parameters and boundary conditions are set, and an initial mold finite element simulation operation is performed to obtain an initial mold simulation result.

[0065] For example, the splitter assembly mold is a complex mold structure, such as Figure 3 and Figure 4 As shown, it is usually composed of multiple functional areas to handle the extrusion process of complex profiles. The die includes the following main parts:

[0066] Divider chamber: responsible for dividing the molten metal material into multiple flow channels so that the material can flow evenly in different flow channels. The design of the diverter chamber has an important influence on the fluidity of the material and the overall performance of the mold.

[0067] Welding chamber: After the molten material passes through the diversion chamber, it converges back into the welding chamber. In the welding chamber, the diverted metal fluid is welded together again as a whole. The design of the welding chamber determines the quality of the material welding and ensures the overall strength and surface quality of the profile after extrusion.

[0068] Core: The core is the core of the mold and determines the final cross-sectional shape of the extruded profile. The shape of the core should be consistent with the designed cross-sectional shape of the profile, and the size, angle and surface quality should be strictly controlled.

[0069] Working zone: The working zone is the part of the mold where the final shaping and extrusion profile flow takes place, which directly affects the surface quality, dimensional accuracy and flow uniformity of the profile.

[0070] Based on the design requirements and shape parameters of the profile, a 3D model of the above mold components is first constructed. This 3D model will serve as the basic input for subsequent finite element simulation.

[0071] After building the 3D model, it is necessary to convert the 3D model into a finite element analysis model. The finite element analysis model is as follows: Figure 5 The construction of the finite element model mainly includes the discretization operation of the model, that is, dividing the continuous three-dimensional model into a finite number of units and nodes for subsequent numerical calculations.

[0072] Meshing: In the finite element model, the three-dimensional model needs to be divided into a large number of small mesh units, which will be used to simulate the mechanical behavior of the material. The density and quality of the mesh directly affect the accuracy of the simulation results. For key areas (such as the diversion chamber, welding chamber, and working zone, etc.), a finer mesh is required to ensure the accuracy of the simulation analysis.

[0073] Extrusion parameter setting: In finite element simulation, it is necessary to input multiple key parameters of the extrusion process, which directly affect the flow behavior of the material and the accuracy of the simulation results. Typical extrusion parameters include:

[0074] Extrusion temperature: refers to the temperature of the material during the extrusion process. Under high temperature conditions, the material has better fluidity, but too high a temperature may cause surface defects.

[0075] Extrusion speed: It is the speed at which the material passes through the die. The speed setting needs to be determined according to the complexity of the profile and the characteristics of the material. Too fast a speed may cause uneven material flow, while too slow a speed will affect production efficiency.

[0076] Extrusion pressure: It is the main driving force for pushing the material through the mold. The distribution and size of the pressure directly affect the flow of the material in the mold.

[0077] Boundary condition setting: Boundary conditions include friction on the mold surface, contact conditions between the material and the mold, etc. These boundary conditions are used to simulate the interaction between the material and the mold in the actual production process, affecting the material flow path and the quality of the final profile.

[0078] After the finite element model is established and the extrusion parameters and boundary conditions are set, the finite element simulation operation begins. The simulation software will simulate the flow, pressure distribution, temperature changes, etc. of the molten metal material in the mold based on the input parameters.

[0079] Diversion chamber: Observe whether the material flows evenly in the diversion chamber, and whether there are dead zones or excessive local flow rates.

[0080] Welding room: Analyze the re-gathering and welding process of materials in the welding room to ensure good welding quality and complete profile structure.

[0081] Working belt: Evaluate whether the material flows evenly in the working belt and whether the expected dimensional accuracy and surface quality can be achieved.

[0082] After the simulation is completed, the simulation results of the initial mold are obtained. The simulation results may include but are not limited to key information such as the flow velocity distribution, pressure distribution, and temperature field distribution of the material in the mold.

[0083] Focus on the velocity uniformity of the profile at the die exit, that is, whether the speed of the material flowing out of the die is consistent. If the simulation results show that there is a large difference in the velocity distribution at the exit, it may cause problems such as uneven size and surface defects in the finished profile.

[0084] If the simulation results show that the material flow is uneven, or the mean square error of the outlet velocity exceeds the preset threshold, the die structure will be optimized and adjusted based on the simulation results. By adjusting the structural parameters of the diversion chamber, welding chamber or working belt, the material flow in the die will be more uniform, ultimately achieving high-quality profile extrusion.

[0085] Specifically, the boundary conditions can be set as shown in Table 1:

[0086]

[0087] Table 1

[0088] This embodiment builds a three-dimensional model of the split flow assembly die and uses finite element simulation to analyze and optimize the die design to ensure the uniformity of material flow and the dimensional accuracy of the finished product. Through this process, the trial and error process in die design can be effectively reduced, and the efficiency and quality of die design can be improved, which is particularly suitable for extrusion molding of complex profiles.

[0089] In some examples, the three-dimensional model is constructed based on any one of UG, SolidWorks and Pro / e three-dimensional software, the finite element simulation operation is performed based on any one of HyperXtrude, Abaqus and Ansys simulation software, and the target mold includes a diversion mold.

[0090] For example, the design process starts with the cross-sectional shape and size of the profile, and UG (Unigraphics NX), SolidWorks, Pro / e (Creo) use 3D software to build the key parts of the diversion die (such as the diversion chamber, welding chamber, mold core and working belt). The geometric size and layout of these parts directly affect the material flow during profile extrusion and the quality of the final product.

[0091] Use finite element simulation software HyperXtrude, Abaqus and Ansys, which can simulate the flow behavior, temperature change and stress distribution of materials in the die, and provide highly accurate simulation results. HyperXtrude: A simulation software specifically used for extrusion process simulation, especially suitable for metal extrusion die design, which can accurately simulate the material flow, temperature field, welding behavior, etc. during the extrusion process. Abaqus and Ansys: These two software are widely used in structural and thermodynamic analysis, and can also simulate the complex behavior of materials during the extrusion process.

[0092] In some examples, calculating the mean square deviation of the profile exit velocity based on the initial die simulation results includes:

[0093] The mean square deviation of the exit velocity SDV is calculated based on the following formula:

[0094]

[0095] In the formula, v i is the flow velocity at the i node on the investigated section; v is the average velocity of all investigated nodes; n is the total number of investigated nodes.

[0096] For example, the profile velocity, temperature, pressure and other distribution diagrams during the extrusion process can be obtained in Hyperview based on the analysis of the simulation results of the initial solution. In general, the uniformity of the profile at the outlet is measured based on the mean square deviation of the profile outlet velocity SDV, and the mean square deviation of the velocity SDV is defined as above. The smaller the mean square deviation of the velocity SDV value, the more uniform the velocity distribution of the profile cross section. The velocity distribution diagram of the profile at the outlet can be as follows: Figure 6 As shown in the figure, the velocity of the outer wall is obviously faster than that of the middle wall, and the velocity of the rib connecting the outer wall and the middle wall is between the outer wall and the middle wall. The maximum velocity of the profile is 155.8mm / s, the minimum velocity is 42.03mm / s, the velocity difference is about 113mm / s, and the velocity mean square deviation SDV is about 36.3mm / s. Obviously, the flow velocity of the metal is very uneven. This velocity distribution will obviously cause serious deformation of the profile, resulting in defects such as bending of the extruded product.

[0097] In some examples, the flow velocity V at the above node is calculated based on the following formula: i :

[0098] V i =m×A i +n×T i +p×R i +q×H i +ξ

[0099] In the formula, A i is the shape factor of the die hole, T i is the temperature of the material to be extruded, L i is the die hole length, R i H is the distance between the die hole and the center of the die, i is the length of the local working zone of the die hole, m, n, p, q are the influencing factors corresponding to each parameter, ξ is a constant determined by other factors in the extrusion process. For the same set of molds, ξ is the same, and for different molds, ξ is different.

[0100] In some examples, the above impact factor is determined based on the following formula:

[0101] m=-157.2+27.205λ

[0102] n=7.42+0.0142λ 2.45

[0103] p=-0.489+0.456e -λ / 6.676

[0104] q=-0.837-1.671λ

[0105] Where λ is the extrusion ratio.

[0106] In some examples, the above structural optimization design operation includes one or more of increasing the size and height of the blocking block, increasing the length of the working zone, and increasing the volume of the intermediate diversion hole.

[0107] For example, in the aluminum alloy extrusion process, there are many factors that affect the metal flow rate, among which the die hole shape, profile wall thickness, distance between the die hole and the extrusion center and the length of the working zone have the most prominent effects on the metal flow rate. According to the results of the first mold design, the mold structure is changed, the size and height of the stop block are increased in places with fast flow speed, the length of the working zone is increased, and the volume of the middle diversion hole is increased. The modified mold can be as follows Figure 7 and Figure 8 The velocity distribution diagram obtained by simulating the modified mold again is shown in Fig. 9 As shown. Fig. 9 It can be seen that the maximum flow rate of the new material is 97.69mm / s, the minimum flow rate is 77.03mm / s, and the speed difference is about 20mm / s. Compared with the first design of the mold, the speed difference is reduced by 93mm / s, and the speed mean square deviation SDV is reduced to 6.6mm / s. The modified mold significantly reduces the degree of deformation of the product. Continuing to analyze the results after the mold modification, the mold structure such as the working belt, the material block, the diversion hole and the welding chamber was fine-tuned to obtain a profile with a more uniform flow rate.

[0108] For example, the structure of the profile has a great influence on the flow rate of the metal. In order to reflect the influence of the die hole shape on the flow rate, the shape factor of the die hole is defined as: A i =L i / C i In the formula, A i is the shape factor, L i is the die hole length, C i is the perimeter of the die hole. From the simulation results of different shapes of profiles in the past, it can be seen that the die hole shape factor and the flow rate always have a good linear relationship, but the growth rate, maximum and minimum values ​​of the flow rate change due to the difference in extrusion ratio of different dies.

[0109] Generally speaking, the thicker the profile wall is, the more favorable it is for metal flow. Based on previous research, it is found that with the profile wall thickness T i Increase, the metal flow velocity at the die hole outlet is positively correlated with the profile wall thickness.

[0110] According to the "concentric circle" rule, as the distance between the profile and the extrusion center increases, the metal flow rate will gradually decrease. The distance between the die hole and the die center is defined as R i From the simulation results, we can see that as the distance between the die hole and the extrusion center (R i ) increases, the corresponding local metal flow velocity shows a linear decreasing trend, and the changing law of the flow velocity corresponding to different die holes is the same, only the flow velocity size changes.

[0111] Define the local working zone length of the die hole as H i The arc-shaped die holes designed at different distances from the extrusion center have different working belt lengths. The extrusion process was numerically simulated using HyperXtrude software, and it was found that the metal flow velocity at the die hole outlet changes. As the working belt length increases, the corresponding local metal flow velocity decreases linearly.

[0112] Through simulation verification, it is found that the die structure and profile structure have a certain relationship on the flow rate. This paper will use the metal flow rate V in the extrusion process i The mathematical model is defined as:

[0113] V i =m×A i +n×T i +p×R i +q×H i +ξ

[0114] In the formula, A i is the shape factor of the die hole, T i is the temperature of the material to be extruded, L i is the die hole length, R i H is the distance between the die hole and the center of the die, i is the length of the local working zone of the die hole, m, n, p, q are the influencing factors corresponding to each parameter, ξ is a constant determined by other factors in the extrusion process. For the same set of molds, ξ is the same, and for different molds, ξ is different.

[0115] Through simulation results, the influencing factors of extrusion ratio are obtained by fitting:

[0116] m=-157.2+27.205λ

[0117] n=7.42+0.0142λ 2.45

[0118] p=-0.489+0.456e -λ / 6.676

[0119] q=-0.837-1.671λ

[0120] Where λ is the extrusion ratio, so the calculation model of flow rate is:

[0121] Vi=(-157.2+27.205λ)A i

[0122] +(7.42+0.0142λ 2.45 )T i

[0123] +(-0.489+0.456e -λ / 6.676 )R i

[0124] +(-0.837-1.671λ)H i +ξ

[0125] The present invention can establish an initial die structure by summarizing the experience of traditional die design and consulting the manual of aluminum profile extrusion die design; then, through the numerical simulation method, the HyperXtrude software based on the ALE algorithm is used for simulation to obtain the physical changes of the temperature field and velocity field of the aluminum profile during the extrusion process. By analyzing these simulation results and combining the structure of the initial die, the volume of the diverter hole, the length of the working belt, the arrangement of the diverter hole, the shape and size of the blocking block and other die structures are modified to optimize the extrusion die that meets the production requirements of complex thin-walled hollow aluminum profiles, and a mathematical formula of aluminum alloy extrusion metal flow rate, extrusion die and extrusion profile structure is also established, which has certain guiding significance for the design of aluminum profile extrusion die.

[0126] like Figure 2 As shown, this application proposes a complex thin-walled hollow aluminum profile mold design device, including:

[0127] A determination unit 21, configured to determine initial mold shape parameter information based on main shape parameter information of a target profile;

[0128] An acquisition unit 22 is used to perform an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result;

[0129] A calculation unit 23 is used to calculate the mean square error of the profile outlet velocity based on the initial mold simulation result;

[0130] The optimization unit 24 is used to perform a structural optimization design operation on the initial mold shape when the outlet velocity mean square deviation is greater than a preset mean square deviation, so that the outlet velocity mean square deviation is less than or equal to the preset mean square deviation, and obtain a corresponding target mold.

[0131] In some examples, initial mold shape parameter information is determined based on main shape parameter information of the target profile;

[0132] Performing an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result;

[0133] Calculate the mean square deviation of the profile exit velocity based on the above initial die simulation results;

[0134] When the mean square error of the outlet velocity is greater than the preset mean square error, a structural optimization design operation is performed on the initial mold shape to make the mean square error of the outlet velocity less than or equal to the preset mean square error, and a corresponding target mold is obtained.

[0135] In some examples, the initial mold finite element simulation operation is performed based on the initial mold shape parameter information to obtain an initial mold simulation result, including:

[0136] Based on the initial mold shape parameter information, a three-dimensional model of a diversion assembly mold is constructed, wherein the diversion assembly mold includes a diversion chamber, a welding chamber, a mold core and a working belt;

[0137] Based on the above three-dimensional model, a finite element model is established, and extrusion parameters and boundary conditions are set, and an initial mold finite element simulation operation is performed to obtain an initial mold simulation result.

[0138] In some examples, the three-dimensional model is constructed based on any one of UG, SolidWorks and Pro / e three-dimensional software, the finite element simulation operation is performed based on any one of HyperXtrude, Abaqus and Ansys simulation software, and the target mold includes a diversion mold.

[0139] In some examples, calculating the mean square deviation of the profile exit velocity based on the initial die simulation results includes:

[0140] The mean square deviation of the exit velocity SDV is calculated based on the following formula:

[0141]

[0142] In the formula, v i is the flow velocity at the i node on the investigated section; v is the average velocity of all investigated nodes; n is the total number of investigated nodes.

[0143] In some examples, the flow velocity V at the above node is calculated based on the following formula: i :

[0144] V i =m×A i +n×T i +p×R i +q×H i +ξ

[0145] In the formula, Ai is the shape factor of the die hole, T i is the temperature of the material to be extruded, L i is the die hole length, R i H is the distance between the die hole and the center of the die, i is the length of the local working zone of the die hole, m, n, p, q are the influencing factors corresponding to each parameter, ξ is a constant determined by other factors in the extrusion process. For the same set of molds, ξ is the same, and for different molds, ξ is different.

[0146] In some examples, the above impact factor is determined based on the following formula:

[0147] m=-157.2+27.205λ

[0148] n=7.42+0.0142λ 2.45

[0149] p=-0.489+0.456e -λ / 6.676

[0150] q=-0.837-1.671λ

[0151] Where λ is the extrusion ratio.

[0152] In some examples, the above structural optimization design operation includes one or more of increasing the size and height of the blocking block, increasing the length of the working zone, and increasing the volume of the intermediate diversion hole.

[0153] like Figure 3 As shown, an embodiment of the present application also provides an electronic device 300, including a memory 310, a processor 320, and a computer program 311 stored in the memory 310 and executable on the processor, and when the processor 320 executes the computer program 311, the steps of any method of designing the above-mentioned complex thin-walled hollow aluminum profile mold are implemented.

[0154] Since the electronic device introduced in this embodiment is a device used to implement a complex thin-walled hollow aluminum profile mold design device in the embodiment of the present application, based on the method introduced in the embodiment of the present application, technical personnel in this field can understand the specific implementation mode of the electronic device of this embodiment and its various variations. Therefore, how the electronic device implements the method in the embodiment of the present application is not introduced in detail here. As long as the equipment used by technical personnel in this field to implement the method in the embodiment of the present application is within the scope of protection of this application.

[0155] In the specific implementation process, when the computer program 311 is executed by the processor, it can achieve Figure 1 Any implementation manner in the corresponding embodiments.

[0156] It should be noted that in the above embodiments, the description of each embodiment has its own emphasis, and for parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0157] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment in combination with software and hardware. Moreover, the present application may adopt the form of a computer program product implemented in one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) that include computer-usable program code.

[0158] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded computer, or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0159] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0160] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0161] An embodiment of the present application also provides a computer program product, which includes computer software instructions. When the computer software instructions are executed on a processing device, the processing device executes the process of complex thin-walled hollow aluminum profile mold design in the corresponding embodiment.

[0162] The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on the computer, the process or function according to the embodiment of the present application is generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions can be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another computer-readable storage medium. For example, the computer instructions can be transmitted from a website site, a computer, a server or a data center by wired (e.g., coaxial cable, optical fiber, digital subscriber line (digital subscriber line, DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) mode to another website site, computer, server or data center. The computer-readable storage medium can be any available medium that a computer can store or a data storage device such as a server or a data center that includes one or more available media integration. The available medium can be a magnetic medium, (e.g., a floppy disk, a hard disk, a tape), an optical medium (e.g., a DVD), or a semiconductor medium (e.g., a solid state drive (SSD)), etc.

[0163] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0164] In the several embodiments provided in the present application, it should be understood that the disclosed systems, devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic. For example, the division of units is only a logical function division. There may be other division methods in actual implementation. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0165] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0166] In addition, each functional unit in each embodiment of the present application may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0167] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application is essentially or the part that contributes to the prior art or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including a number of instructions to enable a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the various embodiments of the present application. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (Read-Only Memory, ROM), random access memory (Random Access Memory, RAM), disk or optical disk and other media that can store program codes.

[0168] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A complex thin-walled hollow aluminum profile mold design method, characterized in that: include: Determine initial mold shape parameter information based on main shape parameter information of target profile; Performing an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result; Calculating the mean square error of the profile exit velocity based on the initial die simulation result; When the mean square error of the outlet velocity is greater than the preset mean square error, a structural optimization design operation is performed on the initial mold shape so that the mean square error of the outlet velocity is less than or equal to the preset mean square error, and a corresponding target mold is obtained.

2. The complex thin-walled hollow aluminum profile mold design method according to claim 1 is characterized in that: The performing an initial mold finite element simulation operation based on the initial mold shape parameter information to obtain an initial mold simulation result includes: Constructing a three-dimensional model of a diversion assembly mold based on the initial mold shape parameter information, wherein the diversion assembly mold includes a diversion chamber, a welding chamber, a mold core and a working belt; A finite element model is established based on the three-dimensional model, and extrusion parameters and boundary conditions are set, and an initial mold finite element simulation operation is performed to obtain an initial mold simulation result.

3. The complex thin-walled hollow aluminum profile mold design method according to claim 2 is characterized in that: The three-dimensional model is constructed based on any one of UG, SolidWorks and Pro / e three-dimensional software, the finite element simulation operation is performed based on any one of HyperXtrude, Abaqus and Ansys simulation software, and the target mold includes a diversion mold.

4. The complex thin-walled hollow aluminum profile mold design method according to claim 1, characterized in that: Calculating the mean square error of the profile exit velocity based on the initial die simulation result includes: The mean square deviation of the exit velocity SDV is calculated based on the following formula: In the formula, v i is the flow velocity at the i-th node on the investigated section; v is the average velocity of all investigated nodes; and n is the total number of investigated nodes.

5. The complex thin-walled hollow aluminum profile mold design method according to claim 4 is characterized in that: The flow velocity V at the node is calculated based on the following formula i : V i =m×A i +n×T i +p×R i +q×H i +ξ In the formula, A i is the shape factor of the die hole, T i is the temperature of the material to be extruded, L i is the die hole length, R i H is the distance between the die hole and the center of the die, i is the length of the local working zone of the die hole, m, n, p, q are the influencing factors corresponding to each parameter, ξ is a constant determined by other factors in the extrusion process. For the same set of molds, ξ is the same, and for different molds, ξ is different.

6. The complex thin-walled hollow aluminum profile mold design method according to claim 5, characterized in that: The impact factor is determined based on the following formula: m=-157.2+27.205λ n=7.42+0.0142λ 2.45 p=-0.489+0.456e -λ / 6.676 q=-0.837-1.671λ Where λ is the extrusion ratio.

7. The complex thin-walled hollow aluminum profile mold design method according to claim 1, characterized in that: The structural optimization design operation includes one or more of increasing the size and height of the blocking block, increasing the length of the working belt, and increasing the volume of the intermediate diversion hole.

8. A complex thin-walled hollow aluminum profile mold design device, characterized in that: include: A determination unit, used to determine initial mold shape parameter information based on main shape parameter information of the target profile; an acquisition unit, configured to perform an initial mold finite element simulation operation based on the initial mold shape parameter information to acquire an initial mold simulation result; A calculation unit, used for calculating the mean square error of the profile outlet velocity based on the initial mold simulation result; The optimization unit is used to perform a structural optimization design operation on the initial mold shape when the outlet velocity mean square deviation is greater than a preset mean square deviation, so that the outlet velocity mean square deviation is less than or equal to the preset mean square deviation, and obtain a corresponding target mold.

9. An electronic device, comprising: A memory and a processor, wherein the processor is used to implement the steps of the complex thin-walled hollow aluminum profile mold design method as described in any one of claims 1 to 7 when executing the computer program stored in the memory.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the complex thin-walled hollow aluminum profile mold design method according to any one of claims 1 to 7 are implemented.

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