Recently a novel multi-container extrusion method has been proposed and proved feasible to simultaneously extrude multiple billets for producing thin-walled wide profiles with reduced force by experiments. Due to its different die structure compared to conventional extrusion methods, the effects of tooling geometries on the multi-container extrusion performance should be comprehensively analysed as the base of die design optimisation. In this study, the original three-container extrusion design and six modified designs were established to investigate the influence of three key geometrical variables, including container diameter, upper die height and welding chamber height, on the extrusion performance through finite element simulation. The considered extrusion performances include metal flow uniformity, extrusion force, welding pressure, die lifetime and material yield. The drawbacks of the original die design were revealed after the primary analysis of the key influencing variables and a three-step way of design improvement was proposed accordingly. Container block and upper die were optimised for the first step; welding chamber height and die bearing length were modified during the second and third steps respectively. Compared with the original design, the final optimised design can decrease the unevenness of the extrudate front shape by 75% and double the material yield, while the extrusion force, die lifetime and welding quality were basically unchanged.

最近提出了一种新颖的多容器挤压方法，并通过实验证明了同时挤压多个坯料以减少力生产薄壁宽型材的可行性。由于其模具结构与传统挤压方法不同，因此应全面分析模具几何形状对多容器挤压性能的影响，作为模具设计优化的基础。在本研究中，建立了原始的三容器挤出设计和六种修改设计，通过有限元模拟研究容器直径、上模高度和焊接室高度等三个关键几何变量对挤出性能的影响。考虑的挤压性能包括金属流动均匀性、挤压力、焊接压力、模具寿命和材料产量。通过对关键影响变量的初步分析，揭示了原模具设计的缺陷，并据此提出了三步设计改进方法。第一步对容器块和上模进行优化；在第二步和第三步中分别修改了焊接室高度和模具轴承长度。与原设计相比，最终优化设计可使挤出物前端形状不均匀度降低75%，材料产量提高一倍，而挤出力、模具寿命和焊接质量基本不变。第一步对容器块和上模进行优化；在第二步和第三步中分别修改了焊接室高度和模具轴承长度。与原设计相比，最终优化设计可使挤出物前端形状不均匀度降低75%，材料产量提高一倍，而挤出力、模具寿命和焊接质量基本不变。第一步对容器块和上模进行优化；在第二步和第三步中分别修改了焊接室高度和模具轴承长度。与原设计相比，最终优化设计可使挤出物前端形状不均匀度降低75%，材料产量提高一倍，而挤出力、模具寿命和焊接质量基本不变。