Abstract
In view of the deflection of metal bars in low-stress cropping process, which leads to serious extrusion damage on the surface of bar and difficulty to apply loads effectively, a “five-segment type” discontinuous variable cross-section bar model is established in this paper. The strain energy method is developed to establish the influence of V-shaped notch parameters on the deflection, and its accuracy is elevated with XFEM method, which is used to quantify the influence of crack depth. Finally, the characterization formula of deflection in the low-stress cropping process is established theoretically. The dynamic and static strain-deflection test and analysis platform is built on the low-stress cropping machine. The experimental results of 45# steel bar confirm the validity of the formula. On this basis, the law θi of follow-up rotation angle of loading die is analyzed, and the effective method to apply desirable loads is obtained. The evaluation parameter ωi(LB/2R0) of allowable value of deflection at crack initiation is proposed, and the allowable deflection range ω1,ω2=0.02343mm,0.15383mm of 45# steel bar with a diameter of 15 mm is given, which can be applied to low-stress cropping and meet the requirements of industrialization.
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