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China Aluminum Network: Designing a structurally sound, cost-effective, and practical extrusion die is an extremely complex and challenging task. As a result, extrusion professionals 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 was primarily based on traditional mechanical design principles, combining strength theory with the designer's hands-on experience. However, as elasto-plastic and extrusion theories advanced, new experimental techniques, computational models, and analytical methods began to be applied in the field of extrusion die design and manufacturing. These include engineering calculation methods, metal flow coordinate grid analysis, photoelastic light-plastic techniques, dense grid pattern methods, slip line theory, upper bound element theory, and finite element analysis. These tools are widely used to determine strain fields, check structural strength, and optimize die geometry and process parameters.
With the rapid advancement of computer technology, CAD/CAM systems for extrusion die design have seen significant development over the past two decades. A large portion of this progress has focused on optimizing die design. 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] utilized AUTOCAD 120 as the graphical platform and Visual Basic 4.0 as the development tool to create a CAD system capable of performing various calculations related to extrusion dies, thereby improving design efficiency. Yan Hong et al. [5] introduced the concept of CAE into die design, highlighting the direction of optimized design. Liu Hanwu et al. [6] proposed the idea of intelligent CAD, offering new insights into the future of automated mold design.
Moreover, 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 in aluminum extrusions. Based on these findings, they have further refined and optimized extrusion dies. For instance, Zhao Yunlu and Liu Jingan [7] systematically explored the optimization of various types of extrusion dies. Some domestic researchers have combined finite element analysis with experimental methods to analyze and improve the profile and structure of extrusion dies. These continuous efforts reflect the growing importance of integrating advanced technologies and scientific approaches into the design and optimization of extrusion molds.
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