Research on the manufacturing of hollow parts with a flange in the process of combined extrusion
DOI:
https://doi.org/10.37142/2076-2151/2025-1(54)15Keywords:
cold bulk forging, extrusion, hollow part with flange, finite element method, mesh distortion, strain intensity distribution, stress intensity distribution, punch, die.Abstract
Kosarev V., Chuchin O. Research on the manufacturing of hollow parts with a flange in the process of combined extrusion
Theoretical studies of the closed combined backward–radial extrusion process of the “Cup with Flange” part made of aluminum alloy A2017 were carried out using the DEFORM 2D/3D software.
The proposed method allowed to completely eliminate the clamping defect and underfilling of the lower corner of the cavity in the flange zone with the workpiece material, due to the use of additional kinematics of both the upper and lower half-matrixes, as opposed to the basic version, in which only the active upper punch was used to deform the workpiece. Elimination of these defects became possible due to the use of additional kinematics of both the upper and lower half-matrixes. The curvature of the dividing grid, the distribution of the intensity of deformations εi and the distribution of the intensity of stresses σi in the cross section of the workpiece being deformed were studied. The study of the graph of the dependence of the extrusion force on the stroke of the upper punch in 73 mm showed that the maximum force value of 160 kN can be seen at the stage of flange formation and complete filling of the cavity in the lower half-matrix with workpiece material. After the flange is formed without defects and the cavity in the lower half-die is completely filled with the workpiece material, the movement of the half-dies changes. Then, towards the end of the process, at the stage of reverse extrusion, the deformation force constantly increases (up to 150 kN).
The results of the theoretical studies can be applied in industrial practice to improve the quality and efficiency of manufacturing “Cup with Flange” parts.
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