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[China Aluminum Network] Designing an extrusion die that is structurally sound, cost-effective, and practical is a highly complex and challenging task. As a result, extrusion workers around the world have conducted extensive research on theories and methods for die design, particularly in the area of optimization. In the early stages of extrusion technology development, mold design relied mainly on traditional mechanical design principles, combined with the experience of engineers. However, as elasto-plastic theory and extrusion theory advanced, new experimental and computational methods began to be applied in the field of extrusion die design and manufacturing. Techniques such as the engineering calculation method, metal flow coordinate grid method, photoelastic light-plastic method, dense grid pattern method, slip line method, upper bound element theory, and finite element analysis are now widely used to determine strain fields and check various strength parameters, ultimately leading to optimized die structures and process parameters.
With the rapid development of computer technology over the past two decades, CAD/CAM systems for extrusion dies have advanced significantly, with a major focus on die optimization. For example, He Delin et al. [3] developed a CAD/CAM system that uses the IDEF0 method to optimize flat and split dies. Wang Mengjun et al. [4] created a CAD system using AutoCAD 120 as the graphic support environment and Visual Basic 4.0 as the development tool, enabling efficient calculations for extrusion die design and improving overall performance. Yan Hong et al. [5] introduced the concept of CAE into the die design process, highlighting the direction for future optimization. Liu Hanwu et al. [6] proposed the idea of intelligent CAD, offering new insights into smart mold design.
Additionally, researchers both domestically and internationally have employed theoretical analysis, physical simulation, and numerical simulation to study the deformation process, stress distribution, temperature changes, and friction behavior during aluminum extrusion. Based on these findings, they have optimized extrusion dies. Zhao Yunlu and Liu Jingan [7] provided a comprehensive discussion on the optimization of various types of extrusion dies. Some domestic researchers have also combined the finite element method with experimental approaches to analyze and improve the profile and structure of extrusion dies, further enhancing their efficiency and performance.
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