Abstract: Resource and environment problems will be the bottleneck of sustainable development in the future, which is significant influence for the transport industry. Therefore, the low fuel consumption, low emission technologies are key technologies in the automotive industry. Lightweight is an effective way to save energy and reduce emission. Aluminum and magnesium alloys are ideal materials for lightweight vehicles due to their high specific strength and high specific stiffness. Considering of the difficulty of extrusion forming and its’ subsequent processing for high-performance aluminum and magnesium alloys, a systematic research has been carried out on extrusion mechanism and precise modeling. A series of high efficiency, short processing extrusion technologies have been developed, including isothermal extrusion based on numerical simulation, extrusion-bending-quenching integration forming and continuous extrusion forming. The new developed extrusion technologies lay a good foundation for the large scale application of aluminum and magnesium alloys in the automobile industry.

Key words: Aluminum alloy, Continuous extrusion forming, Extrusion-bending-quenching integration forming, Isothermal extrusion, Magnesium alloy, Envelope surface, Form grinding, Grinding wheel, Profile calculation, Simulation