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基于Deform-3D有限元软件,以汽车车架用ZK60镁合金带内筋矩形管为研究对象,建立该规格管材穿孔针挤压过程的三维刚塑性有限元模型,并在模拟过程中采用局部网格细化和自适应网格技术。模拟研究发现:运用网格细化和自适应网格技术可有效避免网格过度畸变、折叠等缺陷,提高计算过程的稳定性;该规格ZK60镁合金管材挤压工艺适合选用1000 t铝合金挤压机;当挤压时间t>10 s后,流速均方差降低至Fsdv<2 mm·s-1,流速均匀性得到改善;突破模具的管材温度基本保持稳定或略有上升,在462~484℃范围内。通过挤压实验获得结果与模拟值吻合良好,挤压力最大误差为16.4%,模口管材温度最大误差低于5%。
Based on the Deform-3D finite element software, the 3D rigid-plastic finite element model of ZK60 magnesium alloy strip with rectangular steel tube in the automobile frame was established. The three-dimensional rigid-plastic finite element model of the punching needle was established and the local mesh Gridding and Adaptive Grid Technology. The simulation results show that using grid refinement and adaptive grid technology can effectively avoid defects such as excessive grid distortion and folding, and improve the stability of the calculation process. The ZK60 magnesium alloy pipe extrusion technology is suitable for 1000 t aluminum alloy extrusion When the extrusion time t> 10 s, the mean square error of flow rate was reduced to Fsdv <2 mm · s-1, and the uniformity of flow rate was improved. The temperature of the pipe that broke through the mold basically remained stable or slightly increased. At 462-484 ℃ range. The results obtained by the squeeze test are in good agreement with the simulated values. The maximum squeezing pressure error is 16.4% and the maximum temperature error of the die pipe is less than 5%.