Near Net Forming Research for Fin-Typed LED Radiator

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.