Near Net Forming Research for Fin-Typed LED Radiator

Abstract

Pure aluminum radiator is the best choice for heat dissipation of various LED products at present. Its forming methods include common extrusion, die casting, forging, etc. Compared with other forming technologies, the LED radiator formed by cold forging has good heat dissipation performance, but there are some disadvantages in the forming process, such as uneven deformation, large material consumption and low die life. The cold forging process of pure aluminum fin-typed LED radiator is analyzed by the finite element method. The calculation results show that equal fillet structure of concave die is improper, leading to serious uneven flow velocity distribution during aluminum forging, inconsistent fin length, and warpage tendency. The gradient fillet structure of concave die is adopted. Numerical simulation and production test show that the gradient fillet structure design can significantly reduce the uneven metal flow. The extruded fins have a uniform length, which is conducive to reducing subsequent machining and production cost.

Numerical and Experimental Investigations on Residual Stress and Hardness within a Cold Forward Extruded Preform

“…To enable a fast response to industrial demands such as minimizing lead times and production costs, which is necessary for tool development and prototype fabrication in a cold forging operations, and for product quality verification, various digital twin models have come to be used to assess a plastic’s deformation behavior and its stepwise history of workpiece materials by making virtual predictions and visualizations through a series of FEM (finite element method)-based numerical simulations in implementations that are as similar as possible to an actual forging process [ 1 , 2 , 3 , 4 ]. From the perspective of plastic deformation in the die cavity, proceeding continuously from an initial billet to a target shape, and of the post deformation occurring when a cold deformed product is pulled out from the cavity, and based on empirical assumption that elastic recovery of the workpiece material is small enough to be ignored, numerical predictions and quick visualizations using a series of plastic (or rigid-plastic) material models have been widely and commonly adopted to satisfy the aforementioned industrial needs [ 5 , 6 , 7 , 8 , 9 ].…”