Radially loading rotary extrusion for manufacturing large-size conical cylinders with inner transverse high ribs

Abstract

The Large-size Conical Cylinders with Inner Transverse High Ribs (LCCWITHR) can reduce the weight of the parts while maintaining high rigidity and strength. Radially Loading Rotary Extrusion (RLRE) forming technology can achieve integral forming of LCCWITHR through the synergy of radial and rotary movements of dies. The flow law of the material during the forming process is the key to forming large-size inner ribs. At present, there is no unified understanding of the metal flow law of RLRE forming technology. An analytical expression was derived to predict the Radial Direction (RD) deformation loads. The FE simulation and process experiment were carried out to investigate the effects of the inclination angle, thickness factor and transition arc radius of the split top dies on the spacing of the metal diversion plane, the metal flow velocity of the rib area and the final radius of the inner rib. The influence of the split top dies loading distance and the bottom die rotation angle of each pass on the inner radius of the inner rib was verified. And the optimal combination of dies shape parameters and loading paths which can make the metal flow orderly was obtained: the inclination angle is 140°, the thickness factor is 3.64, the transition arc radius is 16 mm; the top dies loading distance is 15 mm, the bottom die rotation angle is 45°. The FE simulation results have been found to be in close agreement with physics experiment. The research results reveal the metal flow law of rib growth in the RLRE of LCCWITHR, which lays a theoretical foundation for subsequent thorough research and process optimization.