Finite Element Simulation and Warping Influencing Factors of Differential Temperature Rolling 6063/7072 Aluminum Alloy Composite Plate
FU Bangjie1,2, PENG Wenfei1,2,*, LIN Longfei1,2, LI He1,2, SHAO Yiyu1,2, ZHU Shengming1,2
1 College of Mechanical Engineering and Mechanics, Ningbo University, Ningbo 315211, Zhejiang, China 2 Zhejiang Provincial Key Lab of Part Rolling Technology, Ningbo 315211, Zhejiang, China
Abstract: The development of high-energy-density power batteries imposes stringent manufacturing requirements on liquid cooling plates, demanding both high safety and high performance. A novel differential temperature rolling-blowing process is proposed to successfully prepared the 6063/7072 aluminum alloy liquid-cooled plates with excellent bonding and high interface quality for addressing the drawbacks such as low weld reliability and poor interface impact resistance in the traditional stamp-brazing process. However, the heterogeneous metal composite plate is easy to form warping defects after rolling, which leads to the failure of the subsequent blowing process. Therefore, it is urgent to study the warping mechanism and its influence law of the rolled liquid-cooled plate. Through a combination of ANSYS/LS-DYNA finite element simulation and experiments, this paper investigates the warping behavior and mechanism during the differential temperature rolling process, analyzing the impact of process parameters on warpage curvature. The results show that the imbalance of stress in the rolling direction leads to a larger deformation of 6063 aluminum alloy plate than that of 7072 aluminum alloy plate to achieve stress equilibrium of dissimilar metals. The difference of stress in the rolling direction can be used to characterize the warping condition of 6063/7072 aluminum alloy liquid-cooled plates. The warping curvature of the liquid-cooled plate can be effectively reduced by increasing the rolling reduction rate, enlarging the temperature difference between the two types of mental during rolling, and reducing the thickness ratio of 6063 aluminum alloy plate in the composite plate. The forming accuracy of the liquid-cooled plate can be improved by these measures. The relative error between experimental and simulated warping curvature is less than 5.58%. It indicates the accuracy and reliability of the finite element model in this study. The 6063/7072 aluminum alloy composite plate was obtained by differential temperature rolling experiment, which showed that the technical scheme of differential temperature rolling composite plate was feasible. The differential temperature rolling provides an effective approach for the high-performance manufacturing of liquid-cooled plates.
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2024, Vol. 38 
