Numerical Simulation of Uniform Extrusion Forming and Die Structure Optimization of Lightweight Empennage-shaped Component Based on Response Surface Method
In order to solve the problems of non-uniform metal flow and large anisotropy of mechanical properties in forward extrusion forming of lightweight magnesium alloy empennage-shaped component,a metal reservoir die structure is proposedto regulate the uniform metal flow.Based on Deform-3D finite element simulation,the Box-Behnken response surface method is used to establish the response relationship among the mean square difference of metal flow velocity at the exit of die,the forming load and the structural parameters of metal reservoir by taking the depth of h,the length D1 of metal reservoir tank wall from the empennage-shaped core cavity,the length D2 of metal reservoir tank wall from the empennage-shaped cavity,and the angle α between the metal reservoir tank wall and the empennage-shaped cavity as variables.The results of response surface analysis show that the optimal structural parameters of metal reservoir are h=7 mm,D1=13 mm,D2=6 mm,and α=11°.The inhomogeneity of metal flow and the anisotropy of mechanical properties are improvedand the empennage-shaped component with dimensions and mechanical properties that meet the requirements are successfully manufactured using the optimized die structure parameters.
empennage-shaped componentuniform flowfinite element simulationdie optimizationBox-Behnken response surface
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