Forces, stresses and deformations at three variants of cold extrusion of semi-finished products for drawing with thinning
DOI:
https://doi.org/10.37142/2076-2151/2025-1(54)113Keywords:
cold extrusion, hollow semi-finished product, finite element method, forces, specific forces. stresses, strains.Abstract
Kaliuzhnyi O., Kaliuzhnyi V., Solianov D. Forces, stresses and deformations at three variants of cold extrusion of semi-finished products for drawing with thinning
The article uses the finite element program DEFORM and an elastic-plastic metal model to study three variants of cold extrusion of axisymmetric hollow semi-finished products from AISI-1015 steel for drawing with thinning. The variants of the widespread traditional reverse extrusion, direct extrusion with dispensing, and reverse extrusion in a moving die were used. The dependence of extrusion forces, removal of punches from semi-finished products, and pushing semi-finished products out of dies on the movement of the deforming tool was established. A rational option for obtaining semi-finished products for pulling is reverse extrusion with dispensing in a moving die, which provides a lower deformation force compared to reverse extrusion and higher manufacturing productivity compared to direct extrusion with dispensing. For the variant of traditional reverse extrusion and reverse extrusion in a moving die, the modeling results were compared by the distributions of specific forces on the deforming tool, by the distributions of temperature in the volumes of semi-finished products and stress components in the bottom parts of semi-finished products at the end of extrusion, and by the distributions of strain components in the walls and bottom parts. The development of the metal structure by cold plastic deformation along the width of the walls and in the bottom parts of the semi-finished products was evaluated by the distribution and magnitude of the strain intensity. Extrusion in a moving die provides more intensive work along the wall width and in the bottom of the semi-finished product. The shape and dimensions of the semi-finished products were determined. Based on the modeling data, a die for reverse extrusion was designed and manufactured and experiments were conducted on a hydraulic press. The results of the experiments on the extrusion force showed good agreement with the calculated data.
References
Ryu C.H., Joun M.S. Finite element simulation of the cold forging process having a floating die. Journal of Materials Processing Technology. Vol. 112. 2001. Pp. 121-126. https://doi.org/10.1016/S09240136(01)00567-2.
Ji D. S., Jin J. S., Ma W. J. et al. Multistage Cold Extrusion Process and Forming Rules of Shaft Parts Used in Gearbox. Advanced Materials Research. Vol. 148–149. 2010. Pp. 683–687. https://doi.org/10.4028/www.scientific.net/amr.148-149.683.
Jafarzadeh H., Zadshakoyan M., Abdi S.E. Numerical studies of some important design factors in radial–forward extrusion process. Mater Manuf Processes. Vol. 25. 2010. Pp. 857–863. https://doi.org/10.1080/10426910903536741.
Liewald M., Schiemann T., Mletzko C. Automatically Controlled (Cold-) Forging Processes. Procedia CIRP. Vol.18. 2014. Pp. 39–44. https://doi.org/10.1016/j.procir.2014.06.104.
Hosseini S.H., Abrinia K., Faraji G. Applicability of a modified backward extrusion process on commercially pure aluminum. Materials & Design.Vol. 65. 2015. Pp. 521-528. https://doi.org/10.1016/j.matdes.2014.09.043.
Kalyuzhnyi V.L., Aliieva L.I., Kartamyshev D.A., Savchinskii I.G. Simulation of cold extrusion of hollow parts. Metallurgist. Vol. 61(5–6). 2017. Pp.359–365. https://doi.org/10.1007/s11015-017-0501-1.
Noh J.H., Hwang B.B. Influence of punch geometry on surface deformation and tribological conditions in backward extrusion. J Mech Sci Technol. Vol. 32(1). 2018. Pp. 323–331. https://doi.org/10.1007/s12206-0171232-8.
Wang Q., Zhang Zh., Li X. et al. Development of a novel high straining backward extrusion process. MATEC Web Conf. Vol. 190. 2018. https://doi.org/10.1051/mateconf/201819006001.
Petkar P.M., Gaitonde V.N., Karnik S.R. et al. Analysis of Forming Behavior in Cold Forging of AISI 1010 Steel Using Artificial Neural Network. Metals. Vol. 10. 2020 . https://doi.org/10.3390/met10111431.
Kalyuzhnyi V.L., Kalyuzhnyi O.V. (2020). Cold forming of hollow and rod products. Monograph. Kyiv: KIT. 248 p. (in Ukrainian).
Winiarski, G.; Gontarz, A.; Samołyk, G. Theoretical and Experimental Analysis of a New Process for Forming Flanges on Hollow Parts. Materials.Vol. 13. 2020. https://doi.org/10.3390/ma13184088
Aliiev I., Kaliuzhnyi V., Levchenko V. et al. The determination of deformation velocity effect on cold backward extrusion processes with expansion in the movable die of axisymmetric hollow: collective monograph “Mehatronics”. Vol II. Taylor and Francis Group, London. 2021. Pp. 81–100. https://doi.org/10.1201/9781003225447.
Broomand R., Babaei A., Bashiri H. M., et al. Processing MMC tubes via friction stir backward extrusion. Quarterly Scientific Journal of Technical and Vocational University. Vol. 19. 2022. Pp. 225-242. https://doi.org/10.48301/KSSA.2021.287462.1550.
Aliiev I.S., Sivak R.I., Markov O.E. et al. The evaluation of workpiece deformability for the process of two-stage extrusion of hollow hull. Int J Adv Manuf Technol. Vol. 129. 2023. Pp. 1345–1353. https://doi.org/10.1007/s00170-023-12353-6.
Yang Ch., Liu Ch. The Study of Multi-Stage Cold Forming Process for the Manufacture of Relief Valve Regulating Nuts. Applied Sciences. Vol. 13(10), 6299. 2023. https://doi.org/10.3390/app13106299.
Kaliuzhnyi V.L., Markov O.E., Aliieva L.I. et al. Investigation of hot combined extrusion of steel hollow conical parts. J Braz. Soc. Mech. Sci. Eng. Vol.46. 2024. https://doi.org/10.1007/s40430-024-05032-4.
