Extrusion Forming Process And Die Optimization Of Large Contactors

With the development of China's power industry, the high voltage switch manufacturing has also got great development. Contactor is the key part of the high voltage switch with large size and complex shape. The material utilization is low made in traditional mechanical methods, the production efficiency is also low and the mechanical performance is not high. Therefore large contactors of cold extrusion technology is analyzed and studied to solve the problems.The basic principle of the finite element method for metal plastic forming and rigid-plastic finite element simulation software DEFORM are introduced.T2copper cold extrusion process is analysised form the performance and shape, ZF10contactor extrusion parts was designed; Three cold extrusion forming process are made, through comparating a process is determined, and the extrusion process of the ZF10 contactor is given. The parts and sets of dies are made by the three-dimensional modelling software Solidworks, the model of the large contactor is got, the basis for the finite element analysis is provided.The finite element simulation software DEFORM-3D is used to simulate the extrusion, anti-extrusion and upsetting process, and predict the defects, such as collapse horn, filling dissatisfaction, etc. The flow discipline of the metal in the deformation equivalent stress, strain distribution and force-inc curve are obtained. Aimed at the problem of being too much pressure, optimization is proposed, optimization concave die cone angle is proposed. when concave die cone angle is 60,the result is best suitable.In addition different friction conditions to the deformation process of ZF10 contactor is also studied. To the problems of unfilling in upsetting of ZF10 contactor, qualified extrusion mould parts is get through optimizing die. The problem of the cold extrusion forming technology of the part is resolved by cold extrusion forming technology analysis, die design and numerical simulation of forming process to the ZF10 contactor, there has an important role in guiding the process formulating and die design.ZF11 contactor forging is designed through analysising the shape. DEFORM-3D is used to simulate the extrusion and upsetting process, the flow discipline of the metal in the deformation equivalent stress, strain distribution and force-inc curve are obtained. Aimed at the problem of being too much pressure, optimization concave die cone angle is proposed. When concave die cone angle is 90, the result is best suitable. To the problems of folding in upsetting, qualified forging is get through optimizing extrusion. Finally, the simulation result is verified accuracy through the experiment of ZF11contactor.