Fig Fig. 2 Table 1 Actual dimension of part 1 3D 3D model of part Material parameters ε f /% / / MPa MPa ~ ~ 82 80

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1 39 9 Vol. 39 No. 9 FORGING & STAMPING TECHNOLOGY Sep 檪檪檪檪檪檪檪檪 Deform- 3D mm s mm s - 1 Deform-3D DOI /j. issn TG376 A Numerical simulation of the forming process for pressure accumulating tube in automobile accumulator An JingCao YanggenYang ShangleiDeng PeiranCheng LingxiaWu Kaiwei College of Materials EngineeringShanghai University of Engineering ScienceShanghai China Abstract Based on the analysis of the forming process for pressure accumulating tube in automobile accumulator the application of rigid viscoplastic finite element technology and the evaluation standard of the forming load three technological parameters billet temperature die preheating temperature and punch speed influencing the forming process were simulated and analyzed through the orthogonal experiments by Deform-3D software. The optimal technological parameters obtained from experiments are billet temperature 850 die preheating temperature 300 punch speed downwards 16 mm s - 1 during the warm extrusion process and punch speed 8 mm s - 1 for cold extrusion. The numerical simulation results show that both the temperature of warm extrusion billet and punch speed have great effects on forming loadwhile the effect of die preheating temperature is relatively small. In order to reduce the effects of temperature on the forming process the preheating temperature for the die should be relatively high temperature and then during the cold extrusion the punch speed should be relatively small. As a result the qualified forming parts were obtained from actual extrusion with above parameters. Key words pressure accumulating tube extrusion forming forming load Deform-3D software CAE Deform-3D KY051514KY aj1234_ hi@ 163. com cyg-sues@ 163. com aj1234_hi@ 163. com 1 1 UG NX6 2 15

2 Fig Fig. 2 Table 1 Actual dimension of part 1 3D 3D model of part Material parameters ε f /% / / MPa MPa ~ ~ ~ ε = d % = 922 d % 65% < ε f ε = d2 0 - d % = F = 槡 3I2R el 7 100% d d ε p ij = γ 0 槡 3I2 - R el n 槡 3 S ij 8 20% < ε f 2 2 槡 J2 d 0 d 1 d 2 1 ε = F R el n ε + ε = 85% > ε f ε p ij P = Knσ b = MPa = 2002 MPa P MPaK n σ b F = cpa = π N kn 4 F knc A mm 2 2 P = Knσ b = MPa = 539 MPa 5 F = cpa = π 4 N kn 6 20 kn 2 8 γ 0 J 2

3 9 3 T t = T [ ( ) ( ) ( α z ) ] α x α y α z x α T x x + y α T y y + z z α x = λ x α c y p + ω cρ 9 = λ y cp α z = λ z cρ λ x λ y λ z x y z C ρ / Deform-3D AISI-1015 AISI-H W m K mm 2. 4 UG NX6 STL 12 s Deform-3D 2 s ~ ~ Table 2 2 Factor level of warm extrusion test A / B / C / mm s a b Fig. 3 a Warm extrusion test mold Die and blank model b Cold extrusion test mold

4 4 39 Table Factor level of cold extrusion test D / mm s - 1 Deform-3D Table 4 4 Orthogonal table of warm extrusion test A B C Z / 10 4 kn K K K ACB R mm s mm s - 1 Deform-3D kn mm s - 1 Fig. 4 Warm extrusion load-stroke curve after optimization Material temperature is 850 die temperature is 300 and punch speed is 16 mm s kn 5 5 Table 5 Cold extrusion test table D / mm s - 1 Z / 10 kn Fig. 5 Practical formed part

5 9 5 5 Deform-3D mm s mm s Gong HongyingZhu HuiZhao Zhonghuaet al. The cold extrusion forming process optimization about the hexagonal bowl auto part J. IEEE Measuring Technology and Mechatronics Automation ICMTMA Kang H MWang Y SXu L H. Simulation study in warm extruding punch of drilling bit shell J. IEEE Biomedical Engineering and Computer Science ICBECS J Kong X DQuan L X. The historycurrent situation of accumulator's research and its vista J. Machine Tool & Hydraulics Huang C QDeng HDiao J Pet al. Numerical simulation of aluminum alloy hot rolling using deform-3d J. Computer Science and Automation Engineering CSAE J Peng Y HZhou FRuan X Y. Numerical simulation of joint shell extrusion process using 3D finite element method J. Journal of Shanghai Jiaotong University M Hao B H. A Concise Handbook of Extrusion Die Design M. Beijing Chemical Industry Press M Zhang S Z. The Extrusion Process and Die Design M. Beijing Chemical Industry Press M Xie S SLi L. The Metal Plastic Forming Finite Element Simulation Technology and Application M. Beijing Science Press JB /T S. JB /T Process parameters optimization method of orthogonal test method S. 10. M Ren L Q. Experimental Design and Optimization M. Beijing Science Press Deform-3D J Wang PChen YLiu D Fet al. Research on the parameters optimization for externa J boss and ring gear by orthogonal experimental Method based on Deform-3D software J. Machinery Design & Manufacture J Shi W BLiu Z LSun Z Met al. Analysis on warm extrusion processing parameters of spur gear and numberical simulation of die wear J. Forging & Stamping Technology 檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪檪 / 2. 10% logo http www. sxgcxh. org duanya@ cmes. org http www. sxgcxh. org

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