列车车体106XC型材挤压过程数值模拟及模具优化

宋佳胜^{1, 2}，林高用^{1, 2}，贺家健^{1, 2}，刘健^{1, 2, 3}，张振峰³

(1. 中南大学 材料科学与工程学院，湖南 长沙，410083；
2. 有色金属材料科学与工程教育部重点实验室，湖南 长沙，410083；
3. 江阴市江顺模具有限公司，江苏 江阴，214423)

摘 要：以列车车体106XC型材为例进行挤压模具结构设计；在HyperXtrude10.0软件平台上，采用基于任意拉格朗日-欧拉(ALE)网格描述的有限元方法，实现大断面复杂截面铝型材挤压过程的数值模拟。通过增加模芯处引流孔直径、增大引流槽的斜度、调整二级焊合室的大小和工作带长度等措施，对模具进行结构优化，优化后型材最大变形量明显减小，出口处金属流速得到均衡。研究结果表明：数值模拟结果与生产试模结果吻合良好，表明数值模拟结果能为大型复杂截面铝型材挤压模具结构设计提供有效指导。

关键词：列车车体；106XC型材；数值模拟；结构优化

Numerical simulation of extrusion process and die optimization of 106XC aluminum body profile for track vehicle

SONG Jia-sheng^{1, 2}, LIN Gao-yong^{1, 2}, HE Jia-jian^{1, 2}, LIU Jian^{1, 2, 3}, ZHANG Zhen-feng³

(1. School of Materials Science and Engineering, Central South University, Changsha 410083, China;
2. The Key Laboratory of Nonferrous Metal Materials Science and Engineering of Ministry of Education,
Central South University, Changsha 410083, China;
3. Gianshun Mould Co.Ltd, Jiangyin 214423, China)

Abstract:The 106XC body profile of track vehicle was taken as an example to design the extrusion die structure. Based on HyperXtrude software, numerical simulation of aluminum extrusion process with large and complex cross-section were carried out using the arbitrary Lagrange-Eulerian (ALE) finite element method . The optimization for die structure design was finished by increasing the dimension of drainage hole at the die mandrel and the inclination of drainage groove, properly adjusting the volume of the second level welding chamber and die bearing. The maximum deformation of the extruded profile was reduced greatly and the exit velocity of metal was balanced. The virtual extrusion results and experimental extrusion results fit well, indicating that numerical simulation can provide theoretical guide for extrusion die structure design with large and complex cross-section.

Key words:body of track vehicle; 106XC profile; numerical simulation; structure optimization