Investigation On Stamping-forging Hybrid Forming For Thread Plate

With the development of industry, the demand of parts different thickness isincreasing and the requirement is more and more high. The parts with different thicknessare widely used in electronics, automotive, aviation ang space industries. Thread plate areparts with diffrernt wall thickness, its maximum thickness4.5mm and the minimumthickness3mm. Thread is processed on the inner wall for linking with other parts, which isthe characteristic of the threaded plate parts. The traditional methods, such as welding orintegrally cast, cannot meet the requirements for surface quality and strength of join. Thecombination of sheet metal forming and bulk forming generates FCF processing method.FCF method not only ensure the accuracy, strength of the parts and low prod uction costs,but also is fast, efficient and stable quality. In this paper, forging compound formingmethod was used and researched from finite element numerical simulation, Processexperiments and Theoretical calculations three aspects.At first, a theoretical study about the deformation law of the upsetting of thick-walledtubes is done．The velocity field of thick-walled tubes upsetting is established byupper-bound method, the deforming force of upsetting is solved, the radius of shunt layeris derived at last and the key processing parameters of thick-walled tubes upsettingdeformation are analyzed.Secondly, ultimate double drum experiment, largest evenly upsetting-rate in singledrum experiment and largest evenly upsetting-rate with constrained experiment for tubesare made by FEM software DEFORM. The deformation law of the upsetting ofthick-walled tubes is analysed. All of those used as a reference for Upsetting Process.Thirdly, Drawing Technology and Upsetting Process of the thread plate was optimizedby the numerical simulation and analyze the impact of the binder force in the filletbetween punch and punch-die, the gap between punch and punch-die, the frictioncoefficient. Through studing the gap between punch and punch-die, the fillet of punch-dieresearch the material flow of forging process and the impact of the binder shape.Reduction rate of sheet metal is a problem in Drawing Technology, through adjusting thefillet between punch and punch-die can control reduction rate in Drawing Technology. Inthe Upsetting Process adjusting the fillet near the bottom of mandrel can avoid bulking.Finally, according to the theoretical analysis and finite element simulation above,thread plate parts forming process was developed and die was designed. Process experiments of thick-walled pipe fittings. Upsetting law and threaded plates forming weredone, it is found that the theory and simulation results are basically consistent, so thetheoretical calculations and simulation results were proved credibly, the above results hasa certain guidingsignificance on actual production.