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<p>Surging demand for new energy vehicles (EVs) is intensifying industrial challenges in extruding lightweight yet structurally robust aluminum battery tray profiles, particularly in achieving uniform material flow, dimensional accuracy, weld integrity, and closing the gap between extrusion die theory and industrial practice. This study enables the stable extrusion of complex, large-scale, thin-walled, asymmetric 6061-T6 aluminum profiles with multiple cavities through a validated framework that combines die design optimization, finite element analysis, and industrial-scale trials. The developed die has a perimeter of 849.8&#xa0;mm and a circumscribed circle diameter of 379&#xa0;mm, and incorporates a coaxially aligned layout, a butterfly welding chamber, a tapered mandrel with variable bridge widths (30–34&#xa0;mm), a shunt ratio of K₁ = 16, and graded bearing lengths to equalize material flow while minimizing die stress and enhancing dimensional accuracy. Coupled thermomechanical simulations in QForm Extrusion were used to assess load evolution, temperature gradients, stress/strain fields, velocity fields, and weld integrity across a matrix of billet temperatures and ram speeds, identifying 2.5&#xa0;mm·s⁻¹ at 480&#xa0;°C as the optimum operating window. Full-scale trials on a 36 MN extrusion press validated the simulation fidelity, yielding defect-free profiles with contour deviations below 0.1&#xa0;mm and consistent mechanical properties meeting 6061-T6 standards, with tensile strength of 306 ± 25&#xa0;MPa, yield strength of 269 ± 17&#xa0;MPa, and elongation of 11 ± 1%. This work validates the proposed die architecture and processing strategy, providing both theoretical and practical reference for the high-quality manufacturing of lightweight, safety-critical automotive components.</p>

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Extrusion of thin-walled and multi-cavity aluminum battery trays: die design, simulation and process validation

  • 期刊论文

  • 发表日期：

    2026年3月27日

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  • Bo Liu,
  • Chen Wang,
  • Li Zheng,
  • Xuexia Li,
  • Sirun Wang

摘要

Surging demand for new energy vehicles (EVs) is intensifying industrial challenges in extruding lightweight yet structurally robust aluminum battery tray profiles, particularly in achieving uniform material flow, dimensional accuracy, weld integrity, and closing the gap between extrusion die theory and industrial practice. This study enables the stable extrusion of complex, large-scale, thin-walled, asymmetric 6061-T6 aluminum profiles with multiple cavities through a validated framework that combines die design optimization, finite element analysis, and industrial-scale trials. The developed die has a perimeter of 849.8 mm and a circumscribed circle diameter of 379 mm, and incorporates a coaxially aligned layout, a butterfly welding chamber, a tapered mandrel with variable bridge widths (30–34 mm), a shunt ratio of K₁ = 16, and graded bearing lengths to equalize material flow while minimizing die stress and enhancing dimensional accuracy. Coupled thermomechanical simulations in QForm Extrusion were used to assess load evolution, temperature gradients, stress/strain fields, velocity fields, and weld integrity across a matrix of billet temperatures and ram speeds, identifying 2.5 mm·s⁻¹ at 480 °C as the optimum operating window. Full-scale trials on a 36 MN extrusion press validated the simulation fidelity, yielding defect-free profiles with contour deviations below 0.1 mm and consistent mechanical properties meeting 6061-T6 standards, with tensile strength of 306 ± 25 MPa, yield strength of 269 ± 17 MPa, and elongation of 11 ± 1%. This work validates the proposed die architecture and processing strategy, providing both theoretical and practical reference for the high-quality manufacturing of lightweight, safety-critical automotive components.