Abstract
Using the calculation schemes CS-1 (with the presence of a trapezoid module) and CS-1a (with rectangular kinematic modules) has been proposed for the process of the combined radial-direct extrusion of parts with a flange and an axial protrusion. The application of a trapezoidal kinematic module allows the description of the characteristic regions of metal flow, close to the actual course of the process based on the distorted coordinate grids. On the basis of the energy method, the values of the reduced deformation pressure have been obtained using the upper estimate of the power of deformation forces inside the trapezoidal kinematic module. The optimization involved the parameter R k that determines the position of the surface of the interface of metal flow into an axial protrusion and a flange zone. We have performed a comparative analysis of the theoretical calculations of the magnitude of the reduced deformation pressure and the influence of geometric ratios and friction conditions on the qualitative and quantitative differences in the character of the change in the resulting curves. The overestimation of data on assessing the force mode based on the CS-1a scheme relative to the calculations based on the CS-1 scheme can be as high as 50 % and indicates the rationality of using the latter. This is due to the limitation in the use of the optimization (the absence of the optimization of the height of the deformation site) for the scheme containing elementary rectangular kinematic modules. The deviation from the experimentally obtained increments in an axial protrusion does not exceed 7‒10 %, which indicates the validity of the use of the CS-1 estimation scheme with a trapezoidal kinematic module. Thus, it can be argued that it is correct to determine the position of the boundary of the surface of the interface of metal flow into an axial protrusion and a flange zone and the resulting assessment of the formation of a semi-finished product
Highlights
At present, the availability of a variety of methods for processing metals by pressure renders relevance to the task of choosing the most rational and economical method [1,2,3,4,5].Studies of recent years have tackled both the solving of specific practical tasks [1,2,3] and the development of theoretical foundations for modeling the deformation processes
The aim of this study is to develop an estimation scheme for the process of the combined radial-direct extrusion of parts with a flange and an axial protrusion, which could make it possible to effectively predict the shape formation of a semi-finished product
It is promising to assess the possibility of using CS-1 as an autonomous deformation site in the simulation of the initial stage of the trilateral radial-reverse-direct extrusion process
Summary
The availability of a variety of methods for processing metals by pressure renders relevance to the task of choosing the most rational and economical method [1,2,3,4,5]. A steady trend towards expanding the range of stamped parts and materials involving cold extrusion processes necessitates in-depth research and evaluation of the possibilities of expanding the technological capabilities of these processes In this case, studies of recent years have been related to processes that employ both the conventional longitudinal and transverse extrusion schemes and the combined (aligned or sequential) extrusion [7, 8]. A set of studies aimed at developing the procedures for calculating the force regime and predicting the shape formation and defect formation of parts in the processes of combined aligned extrusion is needed. This could encourage their more active industrial implementation
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