针对铜铝无法复合成形和铜铝结合面不紧密等问题，采用Deform－3D有限元软件，模拟了铜铝复合接触线连续挤压包覆成形过程，研究了成形过程不同模芯端部导流角、复合变形区长度、坯料与模具表面状态和挤压轮转速对铜铝复合接触线包覆质量的影响。研究结果表明：模芯端部导流角度取45°～30°，复合变形区长度L取5 mm，铜铝结合紧密度高，包覆效果好；提高铜线与铝线之间的摩擦，降低模具与铜线之间的摩擦，有利于实现铜铝流动的同步性；适当提高挤压轮转速有利于铜铝结合面紧密度的提高。在TLJ340连续挤压机上进行了铜铝复合试验，试验结果与数值模拟结果相吻合，成功生产出质量合格的铜铝复合接触线产品。
Aiming at the problems that the Cu/Al contact wire forming was unsuccessful and the contact of Cu/Al was loose, the continuous extrusion cladding forming process of layered Cu/Al wire was simulated by DEFORM3D. The quality of Cu/Al contact wire under different die core end diversion angle, length of clad forming zone, billet and the die surface state and extrusion wheel speed were systematically investigated. The results show that, when the die core end diversion angle was 45°~30°, the length of clad forming zone was 5 mm, the friction between Al and Cu was increased and the friction between die and Cu was decreased, and the extrusion wheel speed was appropriately raised, all these would be beneficial to the improvement of the compactness of Cu/Al. Based on these results, the Cu/Al contact wire has been tested in TLJ340 machine, the test results verified the simulation ones, and the quality qualified Cu/Al contact wire products have been made.
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