39 9 Vol. 39 No. 9 FORGING & STAMPING TECHNOLOGY 2014 9 Sep. 2014 檪 檪檪檪檪檪檪檪 201620 Deform- 3D 3 850 300 16 mm s - 1 8 mm s - 1 Deform-3D DOI 10. 13330 /j. issn. 1000-3940. 2014. 09. 001 TG376 A 1000-3940 2014 09-0001-05 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 201620China 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 1-4 2013-12 - 16 2014-01 - 20 51075256 13KY051514KY0522 1990 - E-mail aj1234_ hi@ 163. com 1955 - E-mail cyg-sues@ 163. com aj1234_hi@ 163. com 1 1 UG NX6 2 15
2 39 1 5 Fig. 1 1 2 Fig. 2 Table 1 Actual dimension of part 1 3D 3D model of part Material parameters ε f /% / / MPa MPa 15 350 225 70 ~ 73 80 ~ 82 80 ~ 85 1. 1 2. 1 1 2. 1. 1 ε = d2 1 100% = 922 d 2 114 100% 65% < ε f 1 0 2 ε = d2 0 - d 2 2 100% = 1142-110 2 F = 槡 3I2R el 7 100% d 2 0 - d 2 4 114 2-92 2 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 1. 2 6-7 1 P = Knσ b = 1. 1 5. 2 350 MPa = 2002 MPa 2. 1. 2 3 P MPaK n σ b F = cpa = 1. 8 2002 π92 2 4 N 23. 96 kn 4 F knc A mm 2 2 P = Knσ b = 1. 1 1. 4 350 MPa = 539 MPa 5 F = cpa = 1. 5 539 114 2-92 2 π 4 N 2. 88 kn 6 20 kn 2 8 γ 0 J 2
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 2. 2 1 /2 20000 12000 Deform-3D AISI-1015 AISI-H-13 20 0. 04 W m K - 1 1. 6 mm 2. 4 UG NX6 STL 12 s Deform-3D 2 s 3 9-10 3 3. 1 4 11 1 2 3 4 12 15 550 ~ 850 200 ~ 300 2 3 Table 2 2 Factor level of warm extrusion test A / B / C / mm s - 1 1 850 300 8 2 800 280 12 3 750 260 16 3 a b Fig. 3 a Warm extrusion test mold Die and blank model b Cold extrusion test mold 3. 2 9 3
4 39 Table 3 3 1 8 Factor level of cold extrusion test 2 12 3 16 D / mm s - 1 Deform-3D 4 5 4 - Table 4 4 Orthogonal table of warm extrusion test A B C Z / 10 4 kn 1 1 1 1 1. 64 2 1 2 2 1. 67 3 1 3 3 1. 64 4 2 1 2 1. 69 5 2 2 3 1. 66 6 2 3 1 1. 74 7 3 1 3 1. 70 8 3 2 1 1. 93 9 3 3 2 1. 88 K 1 4. 95 5. 03 5. 31 K 2 5. 09 5. 26 5. 24 K 3 5. 51 5. 26 5. 00 ACB R 0. 56 0. 23 0. 31 850 300 16 16 mm s - 1 8 mm s - 1 Deform-3D 4 15700 kn 4 850 300 16 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 - 1 4 20000 3150 kn 5 5 Table 5 Cold extrusion test table D / mm s - 1 Z / 10 kn 1 8 233 2 12 256 3 16 238 8 850 300 5 Fig. 5 Practical formed part
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