Numerical Simulation And Experimental Study On FCF Of Complex Structural Parts

The complex structural parts like the scroll parts of automotive air conditioningcompressor scroll, airbag gas generator housing, radar waveguide pieces, battery caseand so on, are characterized by high thickness radio, smaller wall thickness, the overallstructure of small parts, small overall structure. Such a wide variety of pieces, useinvolves many fields of electronics, automotive, military, aerospace, etc. They areintegral mechanical products and the demand greatly parts. Their dimensional accuracy,surface quality and mechanical properties have high demands. Using traditionalprocessing methods can not meet the production quality assurance, therefore, an urgentneed for an advanced production technology, to overcome the existing deficiencies.This paper is based on FCF, the scroll parts of automotive air conditioningcompressor scroll and radar waveguide pieces are the object of study. By changing thestructure of the mold, applying a reverse force methods to have effective control of anuneven flow in the metal forming process, achieve near net shape of such complexparts. This paper used the DEFORM-3D software to study the two parts of theconventional extrusion and backpressure extrusion to verify the advantage of FCF.Using the orthogonal experiment and gray system theory finished the optimization ofprocess parameters, and grasped the influence of process parameters on the formingeffect. such as backpressure distance, back pressure and extrusion speed. This articleestablished the computational model of forming force and the back pressure of thewaveguide parts, studied the metal flow pattern in the back pressure extrusion process.The results provide reference and guidance to similar parts forming on FCF process.