Predicting the shape formation of hollow parts with a flange in the process of combined radial-reverse extrusion

Abstract

The simulation of the process of combined radial reverse extrusion of hollow parts with a flange has established two fundamentally different, in terms of the components of the kinematic modules, calculation schemes CDZ-1.i and CDZ-2.j, taking into conside ration the possible shape of the boundary of the section of a metal flow inside a workpiece. The comparison of the dependences of the optimal relative rate of metal outflow in the opposite direction for different schemes indicates significant differences in the resulting values in the course of the deformation process. The relevance of this study is due to making it easier to evaluate the use of the combined extrusion process to produce hollow parts with a flange while maintaining the required dimensions compared to simple deformation schemes. We have identified the lack of detailed studies into the technologies for the introduction of combined extrusion schemes, as well as the absence of technological recommendations for determining the force regime and the shape formation of a semi-finished article. The process of the combined extrusion of hollow parts with a flange was investiga ted, thereby selecting different types based on the nature of the metal flow depending on the geometric ratios of the deformation process. We have obtained experimental data on the gradual shape formation of a semi-finished product in the process of deformation at different geometric ratios. The limits of using estimation schemes of the process have been defined to obtain data on the increments in a semi-finished product, including in terms of predicting the formation of a shrinkage cavity in the bottom part. It is recommended that a condition of selecting the appropriate scheme should be the condition for a minimum value of the reduced pressure of deformation i < j. The resulting recommendations make it easier to predict the shape formation and the force mode of extrusion (a deviation from experimentally obtained data can be reduced to 10 %), which would contribute to evaluating the rationality of the combined extrusion processes while ensuring the required dimensions of a part

Designing a kinematic module with rounding to model the processes of combined radial-longitudinal extrusion involving a tool whose configuration is complex

“…The development of capabilities of the energy method of power balance based on the expansion of the base of kinematic modules of complex configuration was addressed in a series of works [29][30][31][32][33][34][35][36]. Papers [29,30] suggested techniques for simplifying the power of plastic deformation forces using a minimizing function in a general form.…”

“…That allowed the authors, among other things, to acquire data on the shape change in a semi-finished article within the ratios of the deformation process chosen for the cited study. The main research results reported in [32,35] make it possible to take into consideration the peculiarities of tool configuration, the shape of the boundaries of the distribution of a metal flow inside the workpiece. The authors identified the complication of the mathematical apparatus when deriving the value of the reduced deformation pressure (in an analytical form) inside the kinematic module of a triangular or trapezoidal shape with slanting boundaries.…”

Process modeling of sequential radial-direct extrusion using curved triangular kinematic module

“…This makes it possible to evaluate the expansion of the technological capabilities of this deformation process. The possibilities of the energy method for obtaining analytical dependencies of the force mode of deformation and features of forming in the processes of combined radial-reverse extrusion are demonstrated in the works [5,15,19,20]. These studies used the kinematic element method to calculate the value of the reduced strain pressure as the total value for the components of unified modules of rectangular, triangular and trapezoidal shapes.…”

Research of the synthesis of radiant intensity indicatrix of multicomponent beam diode module

“…Beam-signal and other devices of active action of the IR range have significant operational advantages at the working lengths of the EMW, which correspond to the "windows" of the transparency of the atmosphere in the middle range of the IR spectrum: (3.3 -4.2) μm, (4.5 -5. 1) μm, (8)(9)(10)(11)(12)(13) μm. Modern technological advances in the production of ultra-bright p-n-emitters in these parts of the spectrum require further study of the mechanisms of formation of the basic physical and technical characteristics of multicomponent beam-diode sources of directional action.…”

“…A simplified parametric model is selected for the empirically obtained data set. Such analytical models are the basis for the classification of the main types of LIC for sources of any radiation mechanism [7,8,9]. Together with the idealized diagram f(θ)=cos -3 •θ (θ -a polar distance) there are 8 such types.…”