The shift to low-carbon economies has spurred the adoption of aluminum profiles in new energy vehicles (NEVs), necessitating advanced die designs for complex structures. This study focuses on critical aspects of aluminum extrusion die design tailored to NEV profiles.
Structural Characteristics
NEV profiles encompass thin-walled floors, beam frames, reinforcing beams, composites, and large-walled hollows. Each type poses unique challenges:
Thin-walled Floors (6063 alloy): Flatness and thickness consistency issues.
Beam Frames (6005/6061 alloy): Multiple cavities and ribs require strong die designs.
Reinforcing Beams (6082 alloy): Thick walls (3.0-18.0mm) pose perpendicularity and flatness challenges.
Composites: Uneven metal flow leads to deformation and surface issues.
Large-walled Hollows: Weld quality affects performance, necessitating optimized seam positions.
Extrusion Processes & Die Design Elements
The extrusion ratio (λ) and pressure (P) are correlated, with λ impacting P. Controlling the dividing ratio (K) reduces extrusion pressure. Die strength and dividing bridge layouts ensure unhindered flow and resistance to pressure.
Key Die Design Points
Dividing Hole Layout: Optimize based on extrusion coefficients, enhancing weld line positions.
Profile Cavity Design: Reduce backhole connections, positioning hollow sections away from the die center.
Die Strength Verification: Ensure through bending and shear stress checks.
Profile Hole Sizing: Adjust for asymmetric tolerances, applying pre-deformation compensation.
Bearing Length Design: Determine based on hole positions and wall thicknesses, using two-stage welding chambers.
Conclusion & Outlook
NEV aluminum profile die design necessitates rational layouts to reduce extrusion pressure and enhance efficiency. Future directions include sophisticated designs with high-quality materials, optimized heat treatment, and rational production processes to cut costs and improve productivity. By comprehensively considering structural characteristics, process requirements, and die strength, aluminum extrusion dies for NEVs can achieve optimal performance.
