Extrusion forming device and method

Abstract

The invention discloses an extrusion forming device and method, the extrusion forming device comprises an extrusion container assembly, a mold assembly and an extrusion assembly, the extrusion container assembly is provided with at least two mutually independent blank cavities, and the cross section of at least one blank cavity is non-circular; the mold assembly comprises a gradual change type flow channel structure, a welding chamber structure and a mold outlet structure, the gradual change type flow channel structure comprises at least two mold flow channels, and the inlet ends of the at least two mold flow channels are in butt joint with the outlet ends of the at least two blank cavities in a matched mode; the at least two mold runners are used for carrying out plastic deformation on the metal blanks in the blank cavities and guiding the metal blanks to the welding chamber structure, and the welding chamber structure is used for carrying out interface welding on metal from the different mold runners; and the extrusion assembly is used for extruding the metal blanks in the at least two blank cavities. The extrusion force can be obviously reduced, the material flow uniformity is improved, the die complexity and material waste are reduced, the profile forming quality is improved, and the service life of the die is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of light alloy profile forming, and in particular to an extrusion forming device and method. Background Art

[0002] With the continuous escalation of demand for lightweight and low-cost manufacturing, the performance requirements for light alloy structural parts in fields such as transportation, new energy, construction, and low-altitude economy are becoming increasingly stringent. In particular, the demand for integrated forming of complex, special-shaped cross-sections, ultra-wide (≥1200mm), and ultra-thin (thickness <1mm) profiles has exceeded the load-bearing limit of traditional extrusion technology. As the core production process for complex light alloy profiles, the technical bottleneck of extrusion technology mainly stems from the inherent limitations of the traditional single circular extrusion barrel structure: during the single-barrel extrusion process, the material flow must overcome extremely high friction resistance. In particular, when extruding ultra-wide and ultra-thin profiles, the extrusion ratio is too large, resulting in a nonlinear increase in extrusion force with the forming width. Taking a 900mm wide aluminum alloy sheet as an example, the required extrusion force is as high as 20,000 tons, which exceeds the tonnage limit of most extruders, forcing companies to rely on multi-pass processing or splicing processes, seriously sacrificing production efficiency and structural strength.

[0003] To overcome the width limitations of single-cylinder extrusion, existing improved processes include curved surface flattening, extended extrusion, flat cylinder extrusion, and multi-cavity extrusion. However, these processes still present significant drawbacks. For example, for wide U-shaped profiles with high ribs at both ends (such as new energy battery trays), the uniform arrangement of the circular cylinders results in insufficient material flow at the edges and severe rib filling defects. For asymmetric aviation skin components, multi-cylinder flow guide designs require the addition of complex flow channel structures to ensure material distribution, increasing mold development difficulty and cost, and requiring lengthy debugging cycles. These issues severely restrict the efficient and low-cost manufacturing of ultra-wide and ultra-thin complex profiles. Existing technologies are no longer able to meet the industry's comprehensive demands for complex cross-sections, extreme dimensions, product quality, and cost control. Summary of the Invention The object of the present invention is to provide an extrusion molding device and method to solve one or more technical problems existing in the prior art and at least provide a beneficial option or create conditions.

[0004] The technical solutions adopted to solve the above technical problems are: The present invention provides an extrusion molding device, comprising: The extrusion cylinder assembly is provided with at least two mutually independent billet cavities, at least two of the billet cavities are arranged through along the extrusion direction, and at least one of the billet cavities has a non-circular cross-sectional shape; A die assembly comprising a gradual flow channel structure, a welding chamber structure, and a die outlet structure that are sequentially connected along the extrusion direction, the gradual flow channel structure comprising at least two die flow channels whose cross-sectional areas continuously and gradually change along the extrusion direction, the inlet ends of at least two of the die flow channels matingly docking with the outlet ends of at least two of the billet cavities, the at least two die flow channels being used to plastically deform the metal billets in each of the billet cavities and guide them to the welding chamber structure, the welding chamber structure being used to perform interface welding on metals from different die flow channels, and the die outlet structure being used to extrude the welded metal in accordance with the cross-sectional shape and size of the target profile; The extrusion assembly is arranged at the inlet end of at least the two billet cavities, and the extrusion assembly is used to extrude the metal billets in at least the two billet cavities.

[0005] The extrusion molding device of the present invention has the following beneficial effects: The invention provides a method for extruding metal blanks in at least two blank cavities through an extrusion assembly, controlling different metal blanks to enter corresponding die runners from different blank cavities for plastic deformation and gradually converge into a welding chamber structure. The metals from different die runners are interface-welded in the welding chamber, and the interface-welded metals are extruded from the die outlet structure to obtain a target product. The invention provides at least two blank cavities within the extrusion barrel assembly, wherein at least one blank cavity has a non-circular cross-section, and the remaining cavities can be circular or other non-circular structures. The cross-sections of the inlet ends of the at least two die runners are strictly matched and docked with the cross-sections of the outlet ends of the at least two blank cavities. The die assembly is provided with a gradual flow channel structure and a welding chamber structure. Each metal blank undergoes plastic deformation under high temperature and high pressure and is interface-welded in the welding chamber structure. Finally, the metal blanks are extruded from the die outlet structure with a cross-section consistent with the target profile at one time. The special-shaped multi-cavity structure realizes blank pre-distribution and synchronous welding. The invention can significantly reduce extrusion force, improve material flow uniformity, reduce mold complexity and material waste, and improve profile forming quality and mold service life.

[0006] As a further improvement of the above technical solution, the arrangement distance and position layout between the billet cavities are adjustable to meet the extrusion requirements of profiles of different widths.

[0007] As a further improvement of the above technical solution, the extrusion cylinder assembly includes an inner lining assembly and an outer lining assembly, the inner lining assembly includes at least two unit modules, the unit module is a tubular structure, at least two of the billet cavities are respectively formed in the tubular cavities of at least two of the unit modules, the outer lining assembly includes a first outer lining body and a second outer lining body that are detachably overlapped with each other, at least two of the unit modules are clamped side by side between the first outer lining body and the second outer lining body, so that the arrangement distance between the at least two unit modules and the number of the unit modules are adjustable.

[0008] As a further improvement of the above technical solution, the extrusion cylinder assembly includes an inner lining assembly and an outer lining assembly, the inner lining assembly includes at least two unit modules, the unit module is a tubular structure, at least two of the billet cavities are respectively formed in the tubular cavities of at least two of the unit modules, the outer lining assembly includes a main lining body, the main lining body is provided with at least two sub-cavities, and at least two of the unit modules are respectively installed in the at least two sub-cavities by interference fit.

[0009] As a further improvement of the above technical solution, the extrusion cylinder assembly includes an inner lining assembly and an outer lining assembly, the inner lining assembly includes a main body module, at least two of the blank cavities are integrally formed in the main body module, the outer lining assembly includes a main lining body, the main lining body is provided with a main hole cavity, and the main body module is installed in the main hole cavity by interference fit.

[0010] As a further improvement of the above technical solution, the extrusion cylinder assembly includes a single piece of mold steel material, and at least two of the billet cavities are integrally formed on the single piece of mold steel material.

[0011] As a further improvement of the above technical solution, the cross-sectional area of ​​the welding chamber structure is arranged to decrease along the extrusion direction.

[0012] As a further improvement of the above technical solution, the mold assembly includes an upper mold and a lower mold arranged in sequence along the extrusion direction, the gradual flow channel structure is arranged in the upper mold, and the welding chamber structure and the mold outlet structure are arranged in the lower mold.

[0013] As a further improvement of the above technical solution, the extrusion molding device also includes an online heating and insulation device and an online temperature sensing and control device. The online heating and insulation device is used to heat and insulate the extrusion cylinder assembly and the mold assembly, and the online temperature sensing and control device is used to monitor and adjust the temperature of the extrusion cylinder assembly and the mold assembly in real time.

[0014] In addition, the present invention also proposes an extrusion molding method suitable for ultra-wide complex cross-section profiles, which is applied to the above-mentioned extrusion molding device. The extrusion molding method includes: Controlling the preheating of the extrusion barrel assembly to a first preset temperature range and the preheating of the mold assembly to a second preset temperature range; controlling heating of different metal blanks to a third preset temperature range; According to the shape matching principle of the target profile, different metal blanks are placed into the corresponding blank cavities respectively; extruding the metal blank in the blank cavity according to a preset pressure; Different metal blanks are controlled to enter the corresponding mold flow channels from different blank cavities for plastic deformation and gradually converge into the welding chamber structure. The metals from different mold flow channels are interface welded in the welding chamber. The metals that have completed interface welding are extruded from the mold outlet structure to obtain the target product.

[0015] Other features and advantages of the present invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a structural schematic diagram of an embodiment of the extrusion molding device provided by the present invention (taking an asymmetric U-shaped cross-section as an example); Figure 2 This is an exploded schematic diagram of an embodiment of the mold assembly provided by the present invention; Figure 3 is a cross-sectional view of an embodiment of a mold assembly provided by the present invention; Figure 4 This is a schematic diagram of a first split structure of an embodiment of the extrusion cylinder assembly provided by the present invention; Figure 5 This is a schematic diagram of a second split structure of an embodiment of the extrusion cylinder assembly provided by the present invention; Figure 6 This is a schematic diagram of the integral structure of an embodiment of the extrusion cylinder assembly provided by the present invention; Figure 7 This is a flow chart of the steps of an embodiment of the extrusion molding method provided by the present invention; Figure 8 1 is a schematic diagram of an asymmetric U-shaped cross-section of an embodiment of the target profile provided by the present invention; Figure 9 This is an axial schematic diagram of an embodiment of the extrusion cylinder assembly provided by the present invention; Figure 10 Schematic diagram of the corresponding relationship between the target profile cross-section and the blank cavity distribution (a), the mold runner outlet cross-section (b), and the welding chamber outlet cross-section (c) of an embodiment of the present invention; Figure Number: Extrusion cylinder assembly 100; billet cavity 110; first billet cavity 111; second billet cavity 112; third billet cavity 113; fourth billet cavity 114; liner assembly 120; unit module 121; outer liner assembly 130; first outer liner body 131; second outer liner body 132; main liner body 133; sub-hole cavity 134; single piece of mold steel material 140; Mold assembly 200; gradient flow channel structure 210; first mold flow channel 211; second mold flow channel 212; third mold flow channel 213; fourth mold flow channel 214; welding chamber structure 220; primary welding chamber 221; secondary welding chamber 222; mold outlet structure 230; upper mold 240; lower mold 250; Extrusion assembly 300; first extrusion rod 310; second extrusion rod 320; third extrusion rod 330; fourth extrusion rod 340; Target profile 400. DETAILED DESCRIPTION

[0017] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0018] In the description of the present invention, it should be understood that descriptions involving orientation, such as the orientation or positional relationship indicated by up, down, etc., are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0019] In the description of the present invention, "a plurality" refers to more than two. The use of "first" or "second" is solely for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of the indicated technical features, or implicitly indicating the order of the indicated technical features.

[0020] In the description of the present invention, unless otherwise clearly defined, terms such as setting, installing, and connecting should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in the present invention based on the specific content of the technical solution.

[0021] The technical solutions of the present invention will be described clearly and completely below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of the present invention, not all embodiments.

[0022] The current extrusion molding process seriously restricts the efficient and low-cost manufacturing of ultra-wide and ultra-thin complex profiles. The existing technology can hardly meet the industry's comprehensive needs for complex cross-sections, extreme dimensions, product quality and cost control. Therefore, the present invention develops an extrusion molding device and method that can synergistically optimize material distribution and flow control, mold life, and complex cross-section adaptability. It has become a key path to break through the bottleneck of light alloy wide profile manufacturing.

[0023] like Figure 1 As shown, the extrusion molding device of the present invention includes: an extrusion cylinder assembly 100, a die assembly 200 and an extrusion assembly 300.

[0024] like Figure 1 As shown, the extrusion cylinder assembly 100 of the present invention is provided with at least two independent billet cavities 110, at least two billet cavities 110 are arranged at intervals along the left-right direction, and at least two billet cavities 110 are arranged through along the extrusion direction. This embodiment defines the extrusion direction as the front-to-back direction, wherein the cross-sectional shape of at least one billet cavity 110 is non-circular, and the remaining billet cavities 110 are circular, elliptical, polygonal or other regular / irregular geometric shapes. The billet cavities 110 can be arranged symmetrically or asymmetrically according to the material distribution requirements of the target profile 400 cross section, and the non-circular billet cavity 110 is a special-shaped cavity, and the cross-section of the special-shaped cavity is square, flat, elliptical, fan-shaped, trapezoidal, etc.

[0025] The arrangement of the blank cavity 110 can be customized according to the cross-sectional characteristics of the target profile 400. For example, for a U-shaped cross-sectional profile that requires a high material filling rate at both ends, an asymmetric combination layout of an outer special-shaped cavity (such as a fan-shaped or trapezoidal) and an inner circular cavity can be adopted to achieve pre-distribution optimization of the blank volume.

[0026] like Figure 1 ,like Figure 2 and Figure 3 As shown, the mold assembly 200 includes a gradual flow channel structure 210, a welding chamber structure 220 and a mold outlet structure 230 that are sequentially connected along the extrusion direction, wherein the gradual flow channel structure 210 includes at least two mold flow channels whose cross-sectional areas gradually change along the extrusion direction, and the inlet ends of at least two mold flow channels match and dock with the outlet ends of at least two blank cavities 110. It can be understood that the cross-sectional shape and size of the inlet end of the mold flow channel correspond one-to-one with the outlet end of the blank cavity 110, forming a gradual flow channel structure 210. At least two molds of the present invention The runner is used to plastically deform the metal billets in each billet cavity 110 and guide them to the welding chamber structure 220. This design significantly reduces the material flow resistance by eliminating the geometric mutation between the circular cavity and the mold runner in the existing multi-circular cavity extrusion, while ensuring that the billets extruded from each cavity are seamlessly connected in the welding chamber. The cross-sectional area of ​​each mold runner is optimized according to the principles of balanced material distribution and balanced flow rate. The mold cavity volume is reduced by 40%-60% compared with the traditional design, effectively reducing metal waste in the material retention area and improving material utilization to more than 90%.

[0027] The welding chamber structure 220 of the present invention is used to perform interface welding on metals from different mold flow channels. The welding chamber structure 220 can be a single-stage or multi-stage structure. Specifically, the cross-sectional area of ​​the welding chamber structure 220 of the present invention is arranged to decrease along the extrusion direction, which is used to ensure sufficient high temperature, high pressure and plastic deformation of the material in the welding chamber, thereby enhancing the interface bonding degree and mechanical properties of the welding interface.

[0028] The die outlet structure 230 of the present invention is used to extrude the welded metal according to the cross-sectional shape and size of the target profile 400 , and the cross-sectional geometric size of the die outlet structure 230 is consistent with the cross-sectional size of the target profile 400 .

[0029] The extrusion assembly 300 of the present invention is arranged at the inlet end of at least two billet cavities 110. The extrusion assembly 300 is used to extrude the metal billets in at least two billet cavities 110. The extrusion assembly 300 of this embodiment includes at least two extrusion rods, and the cross-sectional shape of the extrusion rods is consistent with the corresponding billet cavity 110.

[0030] During use, at least two extrusion rods are used to extrude the metal blanks in at least two blank cavities 110, and different metal blanks are controlled to enter the corresponding mold flow channels from different blank cavities 110 for plastic deformation, and gradually converge into the welding chamber structure 220. The metals from different mold flow channels are interface-welded in the welding chamber, and the metals that have completed interface welding are extruded from the mold outlet structure 230 to obtain the target product.

[0031] To address the technical bottlenecks of traditional single-cylinder extrusion processes, such as high extrusion pressure, uneven material distribution, and short die life, in the extrusion of wide (≥1200mm) and complex-section profiles, the present invention disposes at least two blank cavities 110 at equal or unequal heights within the extrusion barrel. At least one blank cavity 110 has a non-circular cross-section (including square, flat, elliptical, or trapezoidal), while the remaining blank cavities 110 can be circular or other non-circular structures. The blank cavities 110 can be flexibly arranged symmetrically or asymmetrically, with equal or different areas, depending on the cross-sectional characteristics of the target profile 400. The inlet end of the matching mold runner strictly corresponds to the cross-section of the outlet end of each blank cavity 110. The mold assembly 200 is internally equipped with a gradual flow channel structure 210 and a multi-stage welding chamber structure 220. Under high temperature and pressure, each metal blank undergoes plastic deformation and is welded to its interface within the welding chamber. The final product is extruded in one go through a mold outlet structure 230 that matches the cross-section of the target product.

[0032] The present invention realizes blank pre-distribution and synchronous welding through a special-shaped multi-cavity structure. The present invention can significantly reduce the extrusion force, improve the uniformity of material flow, reduce the complexity of the mold and material waste, and improve the profile forming quality and mold service life. It is suitable for the one-time extrusion forming needs of ultra-wide, ultra-thin and complex cross-section light alloy profiles in the fields of rail transportation, new energy, aerospace and low-altitude economy.

[0033] Further, if Figure 1 、 Figure 2 and Figure 3 As shown, the mold assembly 200 of the present invention includes an upper mold 240 and a lower mold 250 arranged in sequence along the extrusion direction, the gradient flow channel structure 210 is provided in the upper mold 240, and the welding chamber structure 220 and the mold outlet structure 230 are provided in the lower mold 250 to facilitate assembly. Different combinations of the upper mold 240 and the lower mold 250 are used according to different profiles.

[0034] In some embodiments, considering that temperature control is very important during extrusion molding processing, in order to achieve precise temperature control, the extrusion molding device also includes an online heating and insulation device and an online temperature sensing and control device. The online heating and insulation device is used to heat and insulate the extrusion cylinder assembly 100 and the mold assembly 200, mainly to preheat and insulate the billet cavity 110, the mold runner and the welding chamber, while the online temperature sensing and control device is used to monitor and adjust the temperature of the extrusion cylinder assembly 100 and the mold assembly 200 in real time.

[0035] In some embodiments, the arrangement distance between two adjacent billet cavities 110 is adjustable, and the position layout is adjustable to meet the extrusion requirements of profiles of different widths, and can be flexibly designed and allocated according to the cross-section of the target profile 400.

[0036] The extrusion cylinder assembly 100 can adopt either of two structural modes: one is a split structure, and the other is an integral structure.

[0037] For the split structure, the present invention proposes two split implementation methods: The first split implementation method: Figure 4As shown, the extrusion cylinder assembly 100 includes an inner lining assembly 120 and an outer lining assembly 130. The inner lining assembly 120 includes at least two unit modules 121. The unit module 121 is a tubular structure. At least two billet cavities 110 are respectively formed in the tubular cavities of at least two unit modules 121. The outer lining assembly 130 includes a first outer lining body 131 and a second outer lining body 132 that are detachably overlapped with each other. At least two unit modules 121 are clamped side by side between the first outer lining body 131 and the second outer lining body 132. In this way, the arrangement distance between at least two unit modules 121 and the number of unit modules 121 are adjustable, so that the arrangement distance between two adjacent billet cavities 110 can be adjusted.

[0038] The first outer lining 131 and the second outer lining 132 apply pressure inwardly through mechanical connection, servo or hydraulic means, thereby fixing the unit module 121, so that a single blank cavity 110 can be maintained and replaced separately.

[0039] The second split implementation method: Figure 5 As shown, the second split-type embodiment differs from the first in the structure of the outer lining assembly 130. The outer lining assembly 130 includes a main lining body 133, and the main lining body 133 is provided with at least two sub-cavities 134. At least two unit modules 121 are respectively installed in the at least two sub-cavities 134 by interference fit.

[0040] Among them, the material of the unit module 121 is hot working tool steel with excellent high-temperature performance, including but not limited to H13, QRO90 or equivalent grade steel. A strength protection layer is also provided between the unit module 121 and the outer lining assembly 130 to improve the overall structural strength and pressure resistance. The main lining body 133, the first outer lining body 131 and the second outer lining body 132 are structures that match the extruder assembly and have heating and insulation functions.

[0041] For the integral structure, such as Figure 6 As shown, the extrusion barrel assembly 100 includes a single piece of die steel material 140 , and at least two blank cavities 110 are integrally formed in the single piece of die steel material 140 .

[0042] The present invention also proposes an extrusion molding method suitable for ultra-wide complex cross-section profiles, which is applied to an extrusion molding device, such as Figure 7 As shown, the extrusion molding method includes: Step S100: controlling the extrusion cylinder assembly 100 to be preheated to a first preset temperature range, and the mold assembly 200 to be preheated to a second preset temperature range; Step S200: controlling the heating of different metal blanks to a third preset temperature range; Step S300: placing different metal blanks into corresponding blank cavities 110 according to the shape matching principle of the target profile 400; Step S400: Extruding the metal blank in the blank cavity 110 according to a preset pressure; Step S500: Control different metal blanks to enter the corresponding mold flow channels from different blank cavities 110 for plastic deformation, and gradually converge into the welding chamber structure 220. The metals from different mold flow channels are interface-welded in the welding chamber. The metals that have completed interface welding are extruded from the mold outlet structure 230 to obtain the target product.

[0043] The present invention provides a production and processing embodiment for preparing an asymmetric wide U-shaped aluminum alloy profile below to describe the above-mentioned extrusion molding device and method in detail: This embodiment adopts the special-shaped four-cavity extrusion method to prepare asymmetric wide U-shaped aluminum alloy profiles, such as Figure 8 As shown, the cross-sectional shape of the target profile 400 is a wide U-shape with a high left side and a low right side. The left high rib specification is 105×1.5mm, the right low rib specification is 40×3mm, the horizontal large surface thickness is 2.5mm, and the total width is 900mm.

[0044] Among them, such as Figure 1 As shown, the extrusion assembly 300 includes a first extrusion rod 310, a second extrusion rod 320, a third extrusion rod 330, and a fourth extrusion rod 340; the extrusion cylinder assembly 100 includes four billet cavities 110, namely the first billet cavity 111, the second billet cavity 112, the third billet cavity 113, and the fourth billet cavity 114; the mold assembly 200 includes an upper mold 240 and a lower mold 250; the upper mold 240 includes four mold runners, namely the first mold runner 211, the second mold runner 212, the third mold runner 213, and the fourth mold runner 214; the lower mold 250 includes a primary welding chamber 221, a secondary welding chamber 222, and a mold outlet structure 230.

[0045] like Figure 9 As shown, the first blank cavity 111 is square (including both types with rounded corners and without rounded corners), with a specification of 80×100 mm, the second blank cavity 112 and the third blank cavity 113 are flat, that is, the upper and lower boundaries are parallel straight lines, and the left and right boundaries are arcs, with a specification of 200×60 mm, and the fourth blank cavity 114 is square, with a specification of 45×70 mm.

[0046] The cross-sectional shape of each extrusion rod is consistent with the corresponding extrusion barrel billet cavity 110 , and the outer dimensions are slightly smaller than the dimensions of the billet cavity 110 by 1-3 mm.

[0047] The inlet cross-sectional shape of each mold flow channel of the upper mold 240 is consistent with the corresponding blank cavity 110, and the external dimensions are slightly smaller than the size of the blank cavity 110 by 2-10 mm; the outlet cross-sectional shape is consistent with the cross-sectional geometric dimensions of the first-level welding chamber 221 of the upper mold 240, the cross-sectional shape of the second-level welding chamber 222 is consistent with the first-level welding chamber 221, and the external dimensions are smaller than the size of the first-level welding chamber 221 by 10-25 mm, and larger than the cross-sectional dimensions of the target profile 400 by 5-10 mm, and the cross-sectional geometric dimensions of the mold outlet structure 230 are consistent with the cross-sectional dimensions of the target profile 400.

[0048] like Figure 10 As shown, each blank cavity 110 performs initial material distribution based on the cross-sectional shape characteristics of the target profile 400. The first blank cavity 111 accounts for 23% of the area, with the material being more distributed vertically; the second and third blank cavities 112 and 113 each account for 34% of the area, with the material being more distributed horizontally; and the fourth blank cavity 114 accounts for 9% of the area, with the material being more distributed vertically. After passing through each mold runner, the material undergoes plastic deformation, and the cross-sectional dimensions of the mold runner outlets change. This allows the outer contour geometry of the mold runners to more closely resemble the cross-sectional shape of the target profile 400 while maintaining the cross-sectional area proportions of each mold runner. After passing through each welding chamber, the material from each mold runner is welded together into a whole and continues to undergo plastic deformation, causing the cross-sectional shape and dimensions of the material at the outlet of the secondary welding chamber 222 to further resemble the cross-sectional shape of the target profile 400.

[0049] The special-shaped four-cavity extrusion method according to an embodiment of the present invention comprises the following steps: Step 1: Preheat the extrusion barrel assembly 100 to 420-480°C, preheat the die assembly 200 to 450-500°C, and lock them both in the extruder; Step 2: Heat the aluminum alloy blank to 480-520° C. and place them into the first blank cavity 111 , the second blank cavity 112 , the third blank cavity 113 , and the fourth blank cavity 114 respectively according to the shape matching principle of the target profile 400 ; Step 3: Start the extruder and push the aluminum alloy billet into the first die runner 211, the second die runner 212, the third die runner 213, and the fourth die runner 214 at a pressure of 550-650 MPa. After plastic deformation, the billet converges into the first welding chamber 221 and the second welding chamber 222, and achieves interface welding at 450-500°C. Step 4: The welded material is extruded through the die outlet structure 230 to obtain an ultra-wide profile.

[0050] Compared with the prior art, the above one or more technical solutions of the present invention have achieved the following beneficial effects: Optimization of extrusion pressure and forming size limits: Special-shaped multi-cavity extrusion technology can flexibly allocate the shape, size, and position distribution of the extrusion barrel cavity according to the cross-sectional shape of the target product. Therefore, compared with circular multi-cavity extrusion technology, it can further reduce the extrusion pressure and expand the width limit and minimum thickness limit of the extrudable profile; Improved mold design efficiency and material utilization: The flexibly distributed special-shaped multi-cavity extrusion cylinder plays an initial role in distributing the billet, which can greatly reduce the design difficulty and cavity complexity of the extrusion mold for complex cross-section profiles, reduce the mold cavity volume, thereby reducing material waste in the cavity and increasing material utilization; Improved product performance uniformity: Since the position, shape and size of the blank cavity 110 of the special-shaped multi-cavity extrusion barrel can be flexibly designed to match the target product cross-section, the uniformity of material distribution and flow deformation during the extrusion process can be greatly improved, resulting in a more uniform microstructure evolution during the extrusion process, making it suitable for high-end application scenarios with strict requirements on mechanical property consistency (such as aviation components).

[0051] Throughout this specification, references to terms such as "one embodiment," "some embodiments," "illustrative embodiments," "example," "specific example," or "some examples" indicate that a particular feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, illustrative uses of these terms do not necessarily refer to the same embodiment or example. Furthermore, the described specific features, structures, materials, or characteristics may be combined in any suitable manner in any one or more embodiments or examples.

[0052] The embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Various changes can be made within the knowledge of ordinary technicians in the relevant technical field without departing from the scope of the present invention.

Claims

1. An extrusion molding device, characterized in that: include: The extrusion cylinder assembly is provided with at least two mutually independent billet cavities, at least two of the billet cavities are arranged through along the extrusion direction, and at least one of the billet cavities has a non-circular cross-sectional shape; A die assembly comprising a gradual flow channel structure, a welding chamber structure, and a die outlet structure that are sequentially connected along the extrusion direction, the gradual flow channel structure comprising at least two die flow channels whose cross-sectional areas continuously and gradually change along the extrusion direction, the inlet ends of at least two of the die flow channels matingly docking with the outlet ends of at least two of the billet cavities, the at least two die flow channels being used to plastically deform the metal billets in each of the billet cavities and guide them to the welding chamber structure, the welding chamber structure being used to perform interface welding on metals from different die flow channels, and the die outlet structure being used to extrude the welded metal in accordance with the cross-sectional shape and size of the target profile; The extrusion assembly is arranged at the inlet end of at least the two billet cavities, and the extrusion assembly is used to extrude the metal billets in at least the two billet cavities.

2. The extrusion molding device according to claim 1, characterized in that: The arrangement distance and position layout between the blank cavities are adjustable to meet the extrusion requirements of profiles of different widths.

3. The extrusion molding device according to claim 2, characterized in that: The extrusion cylinder assembly includes an inner lining assembly and an outer lining assembly, the inner lining assembly includes at least two unit modules, the unit module is a tubular structure, at least two of the billet cavities are respectively formed in the tubular cavities of at least two of the unit modules, the outer lining assembly includes a first outer lining body and a second outer lining body that are detachably overlapped with each other, at least two of the unit modules are clamped side by side between the first outer lining body and the second outer lining body, so that the arrangement distance between the at least two unit modules and the number of the unit modules are adjustable.

4. The extrusion molding device according to claim 1, characterized in that: The extrusion cylinder assembly includes an inner lining assembly and an outer lining assembly, the inner lining assembly includes at least two unit modules, the unit modules are tubular structures, at least two of the billet cavities are respectively formed in the tubular cavities of at least two of the unit modules, the outer lining assembly includes a main lining body, the main lining body is provided with at least two sub-cavities, and at least two of the unit modules are respectively installed in the at least two sub-cavities by interference fit.

5. The extrusion molding device according to claim 1, characterized in that: The extrusion cylinder assembly includes an inner lining assembly and an outer lining assembly. The inner lining assembly includes a main body module. At least two of the blank cavities are integrally formed in the main body module. The outer lining assembly includes a main lining body. The main lining body is provided with a main hole cavity. The main body module is installed in the main hole cavity by interference fit.

6. The extrusion molding device according to claim 1, characterized in that: The extrusion cylinder assembly comprises a single piece of die steel material, and at least two of the blank cavities are integrally formed in the single piece of die steel material.

7. The extrusion molding device according to claim 1, characterized in that: The cross-sectional area of ​​the welding chamber structure is arranged to decrease along the extrusion direction.

8. The extrusion molding device according to claim 1, characterized in that: The mold assembly includes an upper mold and a lower mold sequentially arranged along the extrusion direction, the gradual flow channel structure is arranged in the upper mold, and the welding chamber structure and the mold outlet structure are arranged in the lower mold.

9. The extrusion molding device according to claim 1, characterized in that: The extrusion molding device also includes an online heating and insulation device and an online temperature sensing and control device. The online heating and insulation device is used to heat and insulate the extrusion cylinder assembly and the mold assembly. The online temperature sensing and control device is used to monitor and adjust the temperature of the extrusion cylinder assembly and the mold assembly in real time.

10. An extrusion molding method suitable for ultra-wide complex cross-section profiles, characterized in that: Applied to the extrusion molding device according to any one of claims 1 to 9, the extrusion molding method comprises: Controlling the preheating of the extrusion barrel assembly to a first preset temperature range and the preheating of the mold assembly to a second preset temperature range; controlling heating of different metal blanks to a third preset temperature range; According to the shape matching principle of the target profile, different metal blanks are placed into the corresponding blank cavities respectively; extruding the metal blank in the blank cavity according to a preset pressure; Different metal blanks are controlled to enter the corresponding mold flow channels from different blank cavities for plastic deformation and gradually converge into the welding chamber structure. The metals from different mold flow channels are interface welded in the welding chamber. The metals that have completed interface welding are extruded from the mold outlet structure to obtain the target product.

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