Using simulation to design tool for pressing of hollow profiles from aluminum alloys

Abstract

In order to simulate the pressing of hollow profiles made from aluminum alloys, the previously developed design algorithms for the pressing tool and the QForm software were utilized. The objective of this study was to enhance the quality and decrease the design timeintervals for pressing tools used in the industrial production of aluminum alloy profiles. A novel design procedure for a combined tool, along with the technology of semi-continuous pressing with welded hollow profiles made from aluminum alloys, was proposed. This was achieved using the QForm software, which enables efficient calculations and adjustments of pressing parameters and tool geometry through a dialog interface. The developed algorithm and design procedures enable the drawing of hollow profiles, technological calculations of pressing parameters, selection of a suitable horizontal hydraulic press, matrix and splitter design, determination of strength parameters, assessment of equipment load, and preparation of working drawings for the pressing tool. In order to validate the effectiveness of the design procedure, it was applied to typical hollow profiles fabricated on a commercial scale. Two variations of the pressing tool design were examined. Simulation results obtained from QForm Extrusion software, specifically designed for pressing analysis, revealed that the initial design of the tool, with predetermined technological parameters and geometry of the splitter and matrix channels, resulted in uneven flow of profile elements and temperature distribution. However, by adjusting the tool parameters, it was possible to achieve a straight profile exit from the matrix and a uniform temperature distribution across its cross section. Industrial verification of the designed tool, utilizing a 33 MN hydraulic horizontal press for pressing profiles made from alloy 6063, demonstrated that significant modifications to the matrix and splitter were not necessary. By employing the proposed pressing tool design, batches of products were successfully manufactured in compliance with the required technical specifications, while reducing the design time intervals of the pressing tool by approximately 50 %.