Structural optimization design of extending cavity and die of copper strap produced by continuous extrusion

Abstract

The effect of the extending cavity structure and the calibrating strap length on the uniformity of metal flow were studied by numerical simulation. The metal flow velocity of die inlet, the strain field and the temperature field during the extrusion process was simulated by finite element method. The purpose is to research the effect of extending cavity structure and calibrating strap length on uniformity of metal flow, and then to optimize the structure of extending cavity and die. The results indicate that the extending cavity with a structure of a wide middle part and narrow sides exhibit a more uniform metal flow velocity of die inlet than that with a uniform thickness. Among three structure factors of the extending cavity on the metal flow velocity, the middle-thick of the extending cavity "H" is more significant than the middle width "l" and the thickness of the edge "h" has no significant effect. For the current experimental conditions, the optimum processing parameter of the extending cavity for fabricating the copper strap of 3 mm×100 mm is 62 mm in l, 38 mm in H and 24 mm in h. For the case of fixing the other processing parameters, the 7 mm calibrating strap length can benefit the metal forming, and improve the quality of the copper strap.