Effect of the Die and Tool Structure on Continuous Extrusion Expansion Forming of Copper 

Abstract

Continuous extrusion expansion deforming is an advanced forming process for manufacturing copper bus-bar, die and tool structure is important effect factor of deformation. Based on the characteristics of the forming process, the model of rigid-plastic finite element (FE) on DEFORMT is established and the numerical simulation of continuous extrusion expansion forming process of the copper bus-bar is carried, The metal flow regularity and the mean-square deviation of velocity (SDV) with the different structure of expansion chamber and port hole and die assembled pattern is analyzed. The result show that when using the drum expansion chamber, the trapezium of port hole without transition surface and the die fitted in reverse, the variance of flow velocity is the minimum and deformation is the most homgeneous, the SDV is 0.62. The simulation results provide a theoretical direction for optimization design of die and tool structure of the continuous extrusion expansion forming. Keywords: copper bus-bar, continuous extrusion expansion deforming, die and tool structure optimization, numerical simulation

A Comparative Study on Flat and U-Shaped Copper Strips Produced by Continuous Extrusion

“…The diameters of casting pure copper rods are both Φ30 mm, U-Shaped product size is 420 mm × 14 mm (Figure 2b), and flat size is 300 mm × 14 mm (Figure 2d). Table 1 shows the material properties and simulation parameters [15][16][17]. The distributions of temperature and velocity of metal in the continuous extrusion process were key parameters for the uniformity of the U-Shaped and flat strips.…”