Abstract
It has been proposed to use the developed triangular kinematic module 2a with a curvilinear sloping boundary as an axial one, making it possible to describe the character of metal flow in the reversal zone to radial extrusion. Based on the energy method, we have derived the magnitudes of deformation force power inside the built kinematic module 2a, the power of friction forces at the border of the contact between a blank and a tool, and the power of cut forces with adjacent kinematic modules. The result is the obtained analytical expression of the reduced pressure for the deformation of the axial triangular kinematic module 2a with a sloping boundary, whose shape depends on the parameter α. We have analyzed the possibilities of optimizing the reduced deformation pressure for the parameter α under different ratios of geometric parameters of the module and friction conditions. Taking into consideration the shape of the adjacent kinematic module 3a, it has been proposed to use the resulting reduced pressure dependences to calculate the power modes of the combined sequential radial-longitudinal extrusion processes with the developed radial component of metal flow. A comparative analysis has been performed of the estimation schemes EM-2a with the developed axial triangular kinematic module 2a and EM-2 with the use of the axial rectangular kinematic module 2 and experimental data from modeling the process of combined radial-direct extrusion with expansion. The data on a deformation effort derived from the EM-2a scheme (with the developed triangular module with a curvilinear boundary 2a) and EM-2 exceed those experimentally obtained by 12‒15 % and 15‒20 %, respectively. This confirms the rationality of using the developed axial kinematic module 2a with a curvilinear boundary instead of an axial rectangular kinematic module when modeling processes of the sequential radial-direct extrusion with the developed radial component of metal flow. The resulting dependences of the reduced pressure of the module 2a deformation can be built into other estimation schemes of successive radial-longitudinal extrusion processes. As a result, the decrease in the obtained power parameters of the process could amount to 7‒10 % relative to the schemes involving the axial rectangular kinematic module 2
Highlights
Under current conditions, the role of effective resource-saving methods of metal forming, such as cold bulk stamping, is increasing
There are relevant issues of assessing the power regimes of deformation and predicting shape-change and defect-formation [4, 6, 7]. Resolving these issues would help expand the possibilities of the combined cold extrusion processes and their active implementation in production
The aim of this study is to expand the base of unified kinematic modules by developing a new axial triangular kinematic module with a curvilinear boundary, allowing more complete and accurate modeling of the processes of combined sequential radial-longitudinal extrusion
Summary
The role of effective resource-saving methods of metal forming, such as cold bulk stamping, is increasing. This is primarily due to the decrease in the indicators of energy and labor intensity of production and the increase in the metal utilization coefficient, as well as the increase in its mechanical properties. There are relevant issues of assessing the power regimes of deformation and predicting shape-change and defect-formation [4, 6, 7]. Resolving these issues would help expand the possibilities of the combined cold extrusion processes and their active implementation in production
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