Forward hot extrusion forming process of 4-lobe aluminum alloy helical surface rotor

Abstract

The 4-lobe aluminum alloy helical surface rotors are widely applied in industry, such as superchargers. Generally, the conventional manufacturing processes of aluminum alloy helical surface are time consuming and costly. To make the manufacturing processes more flexible and economical, the forward hot extrusion process is proposed to form the 4-lobe aluminum alloy helical surface rotors. In this work, we implement both simulations and experiments to the forming process of the helical surface, of which the material is 6063 aluminum alloy. The forward hot extrusion process is simulated with finite element method in DEFORM-3D. Based on the simulation method, the influences of different extrusion parameters, such as extrusion temperature, extrusion speed and extrusion ratio, on the extrusion process are studied. According to the numerical simulation results, the optimal case is chosen to carry out the experiment. Furthermore, the experimental results show that the surface is smooth; the toothed fill is full; the twist angle in the length direction is evenly distributed; the value of twist angle is roughly in line with the design angle, which is mainly due to the modified die structure, having a positive and significant effect on the increment of twist angle. Therefore, the twist angle has an increase of about 76%, which verifies the modified die structure.

Keywords

6063 aluminum alloy / helical surface / forward hot extrusion / twist angle / die structure

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