Custom Automobile aluminum profile

In the mold design of automotive aluminum profiles, how to consider the fluidity of aluminum alloys and the stress distribution during extrusion?

In the mold design of automotive aluminum profiles, considering the fluidity of aluminum alloys and the stress distribution during extrusion is a crucial link, which not only directly affects the quality and performance of the product, but also relates to production efficiency and cost control. As a company with deep technical accumulation in the field of aluminum profile design and manufacturing, we deeply understand the complexity of this process, and through continuous technological innovation and practical experience, we optimize the mold design to ensure that the final product can meet the automotive industry's strict requirements for lightweight, high strength and corrosion resistance.
Material property analysis: We deeply analyze the chemical composition, microstructure and thermophysical properties of the aluminum alloy used, especially its melting point, fluidity index and viscosity characteristics. This information is the basic data before designing the mold, which directly affects the key parameters such as the design size of the mold cavity, the inlet angle, and the layout of the diverter cone. Our team uses advanced material science knowledge and experimental data to accurately predict the flow behavior of aluminum alloys in the mold.
Mold structure optimization: Based on the fluidity characteristics of aluminum alloy, we use an optimized diversion system and a reasonable metal flow path when designing the mold to ensure that the molten metal can fill the mold cavity evenly and smoothly, avoiding defects such as local overheating, cold shut and bubbles. For example, by adjusting the number, position and angle of the diversion cones, and optimizing the design of the mold inlet, the flow speed and direction of the aluminum alloy can be effectively controlled to achieve the best filling effect.
Temperature control strategy: The fluidity of aluminum alloy is significantly affected by temperature. We use advanced mold heating and cooling systems to accurately control the temperature of the mold and molten metal to ensure that the aluminum alloy maintains optimal fluidity during the extrusion process. At the same time, by real-time monitoring of the mold temperature, timely adjustment of the heating or cooling strategy, avoid changes in fluidity caused by temperature fluctuations, and ensure the stability and consistency of product quality.
Stress distribution management during extrusion
Stress simulation analysis: Using advanced computer-aided engineering (CAE) software, we perform detailed stress distribution simulation analysis. By simulating the flow, deformation and temperature distribution of metal materials during extrusion, possible stress concentration areas and deformation trends are predicted. This helps to identify and solve potential problems in the mold design stage, reduce the number of mold trials, and shorten the product development cycle.
Mold material selection: In order to withstand the high stress and high temperature during the extrusion process, we use high-performance mold steel materials such as H13, SKD61, etc., which have good thermal stability and wear resistance. At the same time, through heat treatment processes such as quenching and tempering, the hardness and toughness of the mold are further improved to ensure that the mold maintains shape accuracy and stable performance in long-term use.
Mold structure optimization and stress dispersion: In mold design, we focus on stress dispersion design, and reduce stress concentration by increasing fillets, optimizing transition areas, and adopting reasonable mold wall thickness. In addition, by adjusting the width and taper of the mold working zone, the metal flow resistance is optimized to make the stress distribution more uniform, reduce the risk of mold damage, and extend the service life.
Extrusion parameter optimization: Extrusion speed, temperature and pressure are key factors affecting stress distribution. According to the specific characteristics of aluminum alloys and mold design, we determine the best combination of extrusion parameters through repeated experiments and data analysis. This can not only effectively control stress distribution, but also improve extrusion efficiency and product quality.
As a company recognized by many world-renowned certification agencies, we have accumulated rich experience and technical advantages in the field of aluminum profile design and manufacturing. Especially in the field of automotive aluminum profiles, we have successfully provided high-quality lightweight solutions for many well-known automakers. For example, for automotive body structural parts and chassis suspension parts, the molds we designed not only achieve excellent aluminum alloy fluidity control, but also ensure the strength and durability of the products through fine stress management, meeting strict collision test and durability requirements.
Our team not only has many experienced technicians, but also is equipped with advanced and complete top-notch testing equipment in the industry, including film thickness and paint film testers, metallographic microscopes, Vickers hardness testers, etc. These equipment provide us with strong technical support to ensure that each batch of products can meet high precision and high quality standards.