Numerical Simulation Optimization Research of Cold Extrusion Forming for Injection Head
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Abstract:
In order to obtain high-quality injection head, cold extrusion forming is adopted. Based on the study of forming technology for the injection head, reasonable process flow, cold extrusion pre-treatment process and boundary conditions are designed. Two finite element models in forward extrusion and backward extrusion forming ways are established. Taking DEFORM as the platform, the numerical simulation of forming process is carried out. Through simulation, the distribution of strain field, stress field and velocity field in the process of cold extrusion forming is preliminarily forecast, the merits and defects of two kinds of forming processes and the force state of mold are compared , the optimal forming scheme is determined.Keywords:
Stress field
FEM simulation has been widely used in the field of metal forming, such as stamping etc. Numerical simulation technology on mulit-operation sheet forming, however,is still immature nowadays.This paper expounds critical techniques for the multi-operation forming simulation. To demonstrate the application of these techniques, a front door panel forming simulation is carried out.
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The main defect of the inner-hood is break, which was obtained by the numerical simulation of it’s forming process. The main impacted parameters of sheet metal forming process are corner radius of die, friction coefficient, clearance between punch and die and the height of drawbead. The maximum impact of the break of forming factors was drawbead high, followed by the die gap, die edge and the friction coefficient which were obtained by the four factors orthogonal optimized simulation. The comparison between the results of numerical simulation and actual operation proved the accuracy of the numerical simulation.
Stamping
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Based on a new metal forming simulation package,MSC Superforge,the metal flow inside the die in the course of spread extrusion has been simulated and analyzed.The influences of the die parameters including the inflow entry width,outflow exit width,cavity height,basic working land length and flowing hole position on the metal flow have been studied.As a result,the data from that numerical simulation have a significant contribution to the optimization of the design of extrusion dies.
Outflow
Inflow
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Based on the rigid-plastic FEM,numerical simulations of the typical sheet metal with multi-bends are carried out by MSC/superform.have analyzed scientifically the law of metal flow of synchronous forming process of sheet metal with multi-bends.According to the simulation result about stress field,strain field,velocity field and changed load and so on.that can forecast produce defect produced in the course of deformation,offer the reliable reference basis for form- ing this kind of workings,has designed the reasonable die structure which bend-forming of the multi-bends sheet metal bend-forming is coinstantaneous according to the numerical simulation result,through the forming experimental study result show that the bend forming process of sheet metal with multi-bends is realizable.
Stress field
Material Flow
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Simulation software
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The warm extrusion forming of a typical irregular parts with high strength was numerically simulated with MSC/superform. On the base of analyzing extrusion process, the slots were set on forming difficult position to constitute opened-die forming, which can evidently decrease the forming force and improve the quality of the formed parts.
Position (finance)
Base (topology)
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Numerical simulation technology not only could effectively predict the defects on the forming product, such as wrinkle , rupturing, but also could display the stress, strain distribution and forming pressure. The numerical simulation was completed by DYNAFORM solfware, and the result of numerical was using to conduct the double-wall air compressor forming parts forming process inspection and forming mold design optimization.
Roll forming
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In order to realize the forming of a titanium alloy taper,direct extrusion forming process,two-stage extrusion forming process and composite extrusion forming process were designed.The forming loads and production efficiency were contrasted by analysis of Deform finite element software.The best extrusion forming process was selected.The results show that: in the direct extrusion forming process,the maximum load is 11.5MN;in the two-stage extrusion forming process,the maximum load is only 4.25MN,but it has a poorer effectiveness for two-stage forming process;in the composite extrusion forming process,the maximum load is only 38.6% of direct forming process,and it has a higher effectiveness for one-stage forming process.
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Process Simulation
Metal forming
Material Flow
Process design
Design of experiments
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Direct extrusion forming process, two-stage extrusion forming process and composite extrusion forming process were designed for manufacturing a titanium alloy tapered piece. Comparison of the forming loads under the different processes were investigated using Deform finite element method(FEM).Considering the load size, energy consumption and production efficiency, the best extrusion forming process was eventually selected. The result showed that: In the direct extrusion forming process, the maximum load was 11.5MN, and the die life was short; In the two-stage extrusion forming process, the maximum load was only 4.25MN, but it had a poorer effectiveness and higher energy consumption because of two-stage forming processes. In the composite extrusion forming process, the maximum load was only 38.6% of direct forming process, and it had a higher effectiveness and lower energy consumption because of one-stage forming processes.
Titanium alloy
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