Preliminary Study On Forming Laws Of Cuspidal Splitter Split-extruding Rectangular Slot

Slot as a common structure of mechanical parts, have various forming methods. In addition to cutting method, plastic forming can also get slot. In 2006, a literature puts forward a plastic forming method, the name is splitting extrusion. This paper firstly takes rectangular slot splitting extrusion as the research object, in the research the slot width is a constant (10mm). The deformation process of cuspidal splitter split-extruding rectangular slot was researched, and preliminary concluded its forming laws, through numerical and physical simulation methods. The major work and conclusions of the paper are summarized as follows:(1) Proposed the research scheme of cuspidal splitter split-extruding rectangular slot. After some consideration orthogonal test design is used to research this subject. Determined splitter broadening angle, splitter tilt angle, and slot depth as the factors, then every factor takes four level figure, finally selects five-factor and four-level orthogonal table. Used DEFORM-3D (a type of plastic forming finite element analysis soft ware) to do numerical simulation for orthogonal test. According to the forming effect, carried the range analysis. The results of range analysis showed that the primary and secondary relationship between every factor, they are splitter broadening angle (α), splitter tilt angle (β), and the slot depth (δ) in order. According to the range analysis, the optimum parameter isα₁β₁δ₁(α₁=60°,β₁=60°,δ₁=11mm), and the effect tendency graph was drawn.(2) The forming process can divide into three stages, they are start-up stage, stable deformation stage and separate stage, based on the metal flow state in the forming process. Through farther numerical simulation experiment, preliminary concluded some forming laws. The uplift height of slot sides increases with the increase of the slot depth, and showing nonlinear change. The influence width of uplipt increases with the increase of the slot depth, and basically showing linear change. Start-up stage length increases with the increase of the slot depth, and basically showing linear change. Initial side collapse zone length basically not changes with the increase of the slot depth. In the forming process, the maximal deformation influence depth increases with the increase of the slot depth, and basically showing linear change.(3) Refited the existing experimental mold base, used lead brick do the physical simulation experiment. The numerical simulation results of orthogonal test were verified by the physical simulation experiment.(4) For getting rectangular slot without sides uplift directly, researched some blank preforming problem, and designed the preforming blank, the feasibility of preforming blank was verified via the numerical and physical simulation experiment.