Research On Optimization Method For Cold Orbital Forging Process Of Complex-shape Components

Cold orbital forming process is an incremental forming process,which has a lot of advantages,such as saving force,energy and material,high forming accuracy,and good forming quality,playing an important role in the field of precision forming.At present,the cold orbital forming is mainly used for precision forming rotary components with relatively simple shape.As the product design trends to be sophisticated,diversified,and complicated,more and more complex-shape components need to be manufactured accurately and efficiently.In order to make full use of the advantages of cold orbital forming,tap the internal potential of cold orbital forming,and broaden the industrial application of cold orbital forming,in this thesis,the method of combining the finite element simulation and the process experiment is used to study the optimization methods for cold orbital forming of three types of typical complex-shape components(complex sheet parts,components with deep and narrow groove,and face gear with slender shaft),the specific research contents are as follows:(1)Taking the complex sheet component—the cell phone shell as the research object,the laws of the metal flow and the punch filling of the cold orbital forming of the cell phone shell are revealed,and the mechanism of metal deformation inhomogeneity and the discontent of the punch filling in the cold orbital forming process of the cell phone shell is clarified through the finite element simulation and the process experiment.On the basis of the above studies,a new idea that the complex inner surface of cell phone shell can be formed by high dynamic rocking punch is put forward.In order to eliminate the above defects,the optimization method for cold orbital forming of cell phone shell is proposed.(2)Taking the component with deep and narrow groove as the research object,three kinds of metal flow modes of component with deep and narrow groove in cold orbital forming are proposed.The laws of metal flow,punch filling and punch force in cold orbital forming of the component with deep and narrow groove under three kinds of metal flow modes is revealed,and the formation mechanism of some defects of metal folding,underfilling and punch breaking are clarified.On the basis of the above studies,a new idea that improving the stress state of punch by controlling metal flow is put forward.In order to eliminate the above defects,the optimization method for cold orbital forming of mobile phone shell is presented.(3)Taking the face gear with slender shaft as the research object,the laws of the metal flow and the punch filling in the cold orbital forming of the face gear with slender shaft are revealed,and the formation mechanism of some defects of metal folding,underfilling in the cold orbital forming process of the face gear with slender shaft is clarified through the finite element simulation and the process experiment.On the basis of the above studies,the optimization method for cold orbital forming of face gear with slender shaft is put forward.This research has great theoretical and practical engineering value for the establishment of cold precision orbital forming theory for complex-shape components,the development of cold precision orbital forming technology for complex-shape components,and the promotion of industrial application of cold precision orbital forming for complex-shape components.