Structural analysis and optimization of the cold extrusion mould of star sleeve workpiece
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The course of cold extrusion of the star sleeve workpiece is simulated by the 3-D elasto-plastic coupled thermal-mechanical FEA method,using the advanced nonlinear FEA analysis software-MSC.MARC.The stress distribution on the mould is obtained;Then the result is analyzed and a method to reduce the concentration of the stress is found,and so the structure of the mould is modified;The structure is analyzed again based on the new model.The result make a good agreement to the practice and the serve life of the mould is prolonged obviously.This article plays a guiding role on the aspects of simulating the cold extrusion,controlling of the technical parameter and improving the life of the mould.Cite
Based on building the 3-D elastoplastic FEA model on the speed-reducer shaft of auto's Starter and its mould,the process of cold extrusion of the reducer shaft was simulated by the of Numerical Simulation analysis.And the varying rules of extruding forces、velocity、stress as well as metal fluent regulation were obtained.The forming defects occurring in practice were predicted well.The result of simulation makes good agreement to the practice.This research plays a guiding role on the simulation of the cold extrusion,controlling of the technical parameter and the design of the die set.
Starter
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The finite element method was used to analysis the stress in the forging mould of crankshaft blank to solve the long existed problem of the forging mould short working life.A combined structure forging mould was designed and the parameters were determined according to the results of the analysis.The working life of the combined structure mould was several times longer than the original mould.It indicates that the improvement of the mould structure is significant and it is important to use the finite element method in mould design.
Blank
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The forging process and its corresponding die and mould of coupling made by used oil pipe were designed by analyzing the properties of used oil pipe and forging forming process.The die and mould structure was designed by adopting modular and combined type.The inserts with rectangular grooves were used to clamping the blank of coupling.Meanwhile,the reversed cone type design of mandrel was employed and the spherical treatment for its front-end was conducted.Based on the above measures,the efficiency of replacement and maintenance for the die and mould was greatly improved and the use-cost of die and mould decreased observably.Clamping positioning stability of the blank was effectively resolved during the forging process.Moreover,the deform uniformity and stability of opening and closing for the die and mould was well protected during the forming process.The rationality and feasibility of the die-forging process and mold design were validated by the finite element numerical simulation.An effective exploitative way of high value-added is provided to the oil extraction industries through fabricating coupling with used oil pipe.
Mandrel
Blank
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In the tubing extrusion process,the extrusion pressure plays important role in forming the work piec.By using finite element software Deform-3D to carry on the simulation analysis,the paper has discussed the influence of each parameter to the extrusion pressure in the press forming process,so as to achieve the goal of optimizing parameter.
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This paper mainly looks at the research on cold extrusion process and die of vehicle gear sleeve with spline, optimized the cold extrusion process of the part using FEM analysis, which gives us a theoretical basis for further exploration on the cold extrusion, and selecting optimum process parameters. The optimized results were verified by experiments and mass production. It analyzes the effect of the punch shape of gear container to metal flowing. The plastic flow could be controlled by the selection of the punch shape of gear container which reduced the resistance to deformation, and the gear profile was full without folding defects.
Spline (mechanical)
Cold forming
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Cold-and-warm composite extrusion technology with many advantages has been widely used at home and abroad.The technology of spring mandrel and its numerical simulation were introduced.The main parameters were changed including the radii of the die round,the interface friction between the workpiece and die,and temperature of warm extrusion.These parameters showed their influence on the quality of the workpiece and the stress and temperature distributions in the workpiece.The best values of these parameters have been chosen to improve the extrusion process.
Mandrel
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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.
Stress field
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In this paper, the main point of this paper is research on influence of clearance of punching mould on performance of sheet metal forming by using ANSYS software. The stress-strain and deformed mesh are observed and compared with experiment. The results of sheet metal forming simulation analysis are accordant with practice. Finite element method of sheet metal forting provides practicable ways for rapidly and effectively obtaining blank-holder force and clearance of punching mould, validating rationality of mould design, lowering mould design cost and shortening design cycle.
Blank
Design cycle
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Considering the design accuracy of the injection mold of plastic gears,the effect of the thermal deformation on the accuracy was emphatically discussed in this paper.The thermal deformation of a plastic gear was simulated by using the ANSYS and the shape changes of the teeth were obtained between the solidification temperature and room temperature,the results showed that a big error was caused by enlarging the shape of the gear in the design of the injection mold.And the tooth profile obtained by thermal deformation analysis was the most accurate mould cavity,the best-shaped mold cavity can be machined by numerical control WEDM programming.
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In order to reduce the waste of materials and improve proprerties of the product, a new process including hot forging, upsetting combined with extrusion and backward extrusion was proposed. The whole process of manufacturing the support shaft forgings was analyzed and simulated by FEM. According to the predicted result, the reasonable shape and dimensions of the preform were determined. The two sets of extrusion dies of manufacturing the support shaft were designed according to the actual conditions.
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