Research On Compound Forming Process Of Flange With Large Wall Tnickness

Flange is used as a connecting part for various equipments and pipelines or equipments,and has been widely used in industrial production.In view of the application environment of flanged workpieces under pressure and closed connections,the quality of the flanges in engineering is more stringent.According to the actual production requirements,the factory often uses casting,machining,liquid die forging,isothermal plastic forming and other processes to process flanged workpieces with unequal wall thickness.Nowadays the existing stamping process can only process small-walled flanged workpieces.Therefore,this paper proposes a compound forming process to solve the stamping problem of large-walled flange workpieces,thereby expanding the application of stamping process.This paper uses DEFORM-2D/3D finite element simulation software to numerically simulate the upsetting process of the upsetting forming process,studying the upsetting effect and its influencing factors.Aiming at upsetting process,the main process of compound molding,four different configurations of upsetting forming blanks are enumerated firstly in this paper.In the end,an optimal forming solution with rounded corner is obtained,after analysing the forming results of the finite element numerical simulation.By comparing and summing up the influence of the three factors of the rounded structure,the height of the cylinder and friction factor on the forming effect,this paper finds that : there is a certain proportional relationship between the round and the value of the wall thickness,means that there has a great contact of the two;as the friction factor increases,the forming load force also increases significantly;the cylinder height has little effect on the forming shape effect,but it has the same effect of the load force as the frictions'.On the premise of guaranteeing the forming effect,this paper summarizes the optimum process parameters for the processing of large-thickness flange workpieces—the roundness R?3.33 t,the friction factor 0.1,the straight height 30 mm,and the straight wall thickness forming extreme T,about 1.5~1.867 times the wall thickness t.This paper studies the metal flow law and stress-strain relationship in upsetting process under four modes,and comprehensively analyzes the causes of defects in upsetting process.Finally,in order to verify the correctness of the finite element simulation results and the feasibility of the process,a verification test was designed.The experimental results are in good agreement with the expected set value,which provide the guidance for the optimization of the process and the actual production.