大宽厚比铜排连续挤压物理模拟与生产实践

【作者】 代娜娜；

【导师】 钟毅；

【作者基本信息】 昆明理工大学 ， 材料成型与控制， 2012， 硕士

【摘要】 各种规格的铜导电排在工业电力传输中扮演着重大作用,具有巨大需求,铜排的传统生产方法为挤压、轧制或是挤压与轧制相配合,但传统的生产方法工艺流程长,设备资金投入巨大。连续挤压技术由于其节能、高效、短流程、近终形、设备资金投入小、铜排组织性能优越等优势,已经基本取代铜排的传统生产工艺。但是在采用连续挤压技术开发大宽厚比大截面铜排的过程中,由于需要进行大扩展比的变形,导致铜排在成形过程中金属流动不均匀,产生裂边、色差、产品横向组织不均匀以及存在厚度尺寸差等问题。目前,TJ550型连续挤压机生产的铜排,其最大生产尺寸为204.5mm×15mm,其扩展比为9.30,宽厚比为13.6。为了实现204.5mm×7.5mm尺寸铜排的产品研发,本文采用物理模拟技术和现场试验相结合的方法,对连续挤压大截面大宽厚比铜排的模具结构设计进行研究。物理模拟采用橡胶泥作为模拟材料,将有机玻璃加工成1：1的工装模具,根据橡胶泥在模具中的流动规律,初步确定模具结构,进行生产用模具的设计与制造,在TJ550型连续挤压机上进行现场试验,再根据试验结果进行适当的模具修正。通过研究获得了连续挤压大扩展比及大宽厚比铜排的模具设计规律,包括大扩展比所需的“哑铃状”导流槽结构参数、定径带宽度、阻流面宽度及阻流角度沿产品宽度方向的变化规律。据此设计了三种具有大扩展比及大宽厚比的产品模具,经现场试验,在TJ550型连续挤压机上对204.5mm×7.5mm规格铜排(扩展比为9.30,宽厚比为27.27)进行试生产时,消除了产品裂边,减小了产品色差及横向厚度不均匀。论文最后对采用连续挤压技术生产铜铝合金的大型整体壁板型材的前景进行了展望。更多还原

【Abstract】 The copper conductive bus bar be playing an important role in the industrial power transmission. The traditional production processes of copper bus bar were the extrusion, rolling or extrusion-rollingusion. However, the traditional processes were multi-process, with expensive equipment. The traditional production processes almost be replaced by Continuous Extrusion technology, because of these technical advantages of Continuous Extrusion as energy saving, high efficiency, short process and near net shape, equipment inexpensive, good performance of production, etc. But the productions made by Continuous Extrusion were defect as cleft edge, color, uneven lateral grain size, and thickness of the size difference because the uneven metal flow in the process of large expansion, for the copper bus bar were produced by large width-to-thickness and large cross-section by Continuous Extrusion.Currently, the maximum size of the copper bus bar produced by TJ550type CONFORM equipment was204.5mm X15mm,and the expansion ratio was9.30,the width-thickness ratio was13.6. In this thesis, for204.5mmX7.5mm copper bus bar research, the die structure was studied by the Physical Model and field trial combining for the copper bus bar with large width to thickness ratio and large cross-section by CONFORM. The plasticine was used be model material in the physical modeling, the plexiglasses was be made to the tooling die by the ratio1:1.The die structure initially identified according to the law of plasticine flow in the plexiglasses, the actually die was designed and manufacturing for the field experiment by TJ550type CONFORM equipment. The die was be made appropriate correction according to the field trial.The law of die designed was got by these research for the copper bus bar with large width-to-thickness ratio and large cross-section by CONFORM equipment, include the structural parameters of dumbbell-shaped, the changes of bearing lengths width、baffles height and baffles angle along the width direction of the product. Three kinds of extrusion die with high expansion ratio and width-to-thickness ratio have been designed according the rules proposed above. Field trial was carried out by using a TJ550type CONFORM equipment producing copper bus bar with a specification of204.5mm×7.5mm, of which the expansion ratio reaches9.30, and width-to-thickness ratio reaches27.27Results of trial production shows the defect of edge crack has been eliminated, and the inhomogeneity of surface color and transverse thickness of product has been decreased.Finally, there is a forecast about the use of conform technology in the production of large overall for copper\aluminum siding profiles in this thesis.更多还原