Simulation and Experiments on Fabrication of Strain Controllable Aluminum Strips by Stepped Rake Angle Tool

doi:10.16183/j.cnki.jsjtu.2024.107

Abstract

Abstract:

The reduction of the tool rake angle in the extrusion machining process is conducive to increase the shear strain and grain refinement, but it easily leads to problems such as strip extrusion difficulties and poor surface quality. To improve the forming quality of ultrafine-grained aluminum strips and to realize the controllable strain distribution adjustment, a new process of extrusion machining with a stepped rake angle tool is proposed. By combining simulation and experiments, the strip morphology, microhardness, and microstructure of 6061 aluminum alloy under different machining parameters are investigated. Extrusion machining with conventional rake angle tool is also conducted as a comparative test. The results show that the stepped rake angle tool achieves the continuous formation of ultrafine-grained strip with different strain distributions within the strip, and the ratio of high and low strain zones is adjustable by changing the cutting thickness. This process can provide ideas and methods for tool design and ultrafine-grain material preparation.

Key words: ultrafine-grained strip, forming quality, strain distribution, stepped rake angle tool, 6061 aluminum alloy

CLC Number:

TG506
TH162

ZHONG Peixuan, ZHANG Baoyu, LI Songqing, SHEN Pengyu, DENG Wenjun. Simulation and Experiments on Fabrication of Strain Controllable Aluminum Strips by Stepped Rake Angle Tool[J]. Journal of Shanghai Jiao Tong University, 2026, 60(2): 338-348.

Figures/Tables 19

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化学成分	质量分数/%
Mg	1.02
Si	0.69
Fe	0.43
Cu	0.40
Cr	0.35
Zn	0.25
Mn	0.15
Al	余量

参数	取值
温度/℃	20
刀具速度/(mm·s^-1)	105
摩擦因数	0.2
单步步长/mm	0.02
步数	1 500

t₀ /mm	等效应变模拟值	等效应变计算值	相对误差/%
0.3	3.99	3.93	1.5
0.4	3.72	3.81	2.4
0.5	3.50	3.30	5.7
0.6	3.29	3.13	4.9
0.7	3.09	2.97	3.9
0.8	2.93	2.80	4.4

加工参数	Sa最大值/μm	Sa平均值/μm	标准差/ μm
CRA,γ=5°,t₀=0.5 mm	28.613	23.647	4.967
CRA,γ=20°,t₀=0.5 mm	12.754	10.605	2.149
SRA,t₀=0.5 mm	20.710	17.118	2.792
SRA,t₀=0.3 mm	23.289	19.118	4.028
SRA,t₀=0.7 mm	11.835	10.289	1.546