高強度鋁合金中空方形有縫管擠製製程與模具銲合室設計之模擬分析

Simulation Analysis on the Extrusion Process and the Die Design of the Welding Chamber of the Hollow Square Seam Tube in High Strength Aluminum Alloy

許志鵬(Chih-Peng Hsu) ； 許光城(Quang-Cherng Hsu) ； 蔡秉訓(Ping-Hsun Tsai)

《鍛造》 19卷1期 (2010/03) Pp. 9-15

https://doi.org/10.29791/Forging.201003.0002

摘要

鋁合金7000系列具有強度高、質量輕的特性，目前擠製品多以實心擠型為主，運用在運輸工具結構及運動產業。在管件方面，因7000系列鋁合金有些材質(7050/7075)具有不易銲合特性，故擠製以無縫管為主。然對於產品應層面來說，中空複雜型鋁擠產品仍占多數，且因為鋁合金七千系列中之7075擁有比一般6000系列材料更良好之特性，包含優異的強度與韌性等，因此若能擠製7075有縫中空製品，將帶給產業更多優異的產品應用，並能提升擠型產品的使用效益。因此本研究針對高強度鋁合金中空方形有縫管，進行擠型製程與模具銲合室設計之模擬分析，希望提高擠製良率，完成高品質之7075有縫中空管件之擠製。模擬分析研究期望經由合適之模具銲合室設計以增加7075在銲合室之銲合壓力，以克服7075熔接性不良的問題。因7075較一般鋁合金熔接性差，需在足夠的熔接壓力、適合之胚料溫度、較慢之擠型速度(較長之熔合時間)條件下，才能得到一定程度的熔接強度。本文中，考慮銲合室高度及寬度、模具承面長度、公模熔接室深度等模具設計參數，利用有限元素軟體DEFORM 3D分析模擬7075中空方形有縫管擠型製程與模具銲合室等設計參數。此外本文利用田口法對模具設計參數最佳化，以得到較高熔接壓力，期望得知7075高強度鋁合金分流銲合條件，研究結果顯示，銲合室結構中其高度與長度比例為2:1時可增加銲合壓力之效果最顯著，銲合面壓力約可達到500MPa以上之壓力。

關鍵字

擠型 ； 高強度鋁合金 ； 銲合室 ； CAE ； 中空方形有縫管

並列摘要

AL-7XXX series are strong and light weight. Its products are usually solid extrusions, and applied to structure of transportation and sport industries. Some of AL-7XXX series, like 7050 and 7075, have poor weldability, are mainly extruded into seamless tube. Nevertheless, according to product application, the majority products are hollow complicated shape extrusion. 7075 has better properties, like excellent strength and tenacity, than 6XXX series. If hollow seam product can be extruded by 7075, industries can find more product applications and increase the benefits of using extrusions.This research focus on extrusion of high strength aluminum alloy hollow square seam tube. In this case, extrusion process and welding chamber design and simulation are done to improve the Yield Rate of extrusion, and achieve high quality 7075 hollow seam tube extrusion. Because of the poor weldability of 7075, sufficient welding pressure, appropriate billet temperature, slower extrusion speed (longer welding time) are required to get the particular welding strength. To overcome the poor weldability of 7075, die welding chamber design and its simulation are done to improve the pressure of chamber. In this study, height, width, depth of welding chamber, bearing length, and the other design parameters are considered and DEFORM-3D is applied to analyze the process of 7075 hollow square seam tube and the design parameters of die. Expecting to get the welding conditions of 7075 high strength aluminum alloy, we also use Tagushi method to optimize die design parameters and obtain higher welding pressure. The results of this research disclose that when the ratio of height and length is 2:1, the effect of increasing the welding pressure is conspicuous, and the pressure of welding surface is about 500MPa.

並列關鍵字

Extrusion ； High Strength Aluminum Alloy ； Welding Chamber ； CAE, Hollow Square Seam Tube