Nosov Magnitogorsk State Technical University (Magnitogorsk, Russia):

Zhelezkov O. S., Dr. Eng., Prof., Chair “Engineering Mechanics and Structural Resistance”, e-mail: ferumoff@mail.ru
Malakanov S. A., Cand. Eng., Head of Department, e-mail: samalakanov@mail.ru
Platov S. I., Dr. Eng., Prof., Head of the Chair “Equipment and Technologies of Metal Processing”, e-mail: mitod_@mail.ru

The article presents the results of simulation of drawing process for hexagonal sections from round billets through dies of various designs. Drawing in several passes of a round billet through polyhedral monolithic dies with intermediate operations (such as annealing, surface preparation, etc.) is the most common method of manufacturing of hexagon sections. The large number of technological operations is considered as the main deficiency of the applied technology. Simulation of the drawing process for hexagonal shapes from round billets is conducted using the finite element method. The processes of drawing of hexagonal sections through a die with flat faces and a die with ledges in the working area were investigated. The data on the stress-strained state were obtained and the fi elds of distribution of the radial, circular and axial stresses in the billet during drawing were built. It was found that the ledges in the working area of the die favor formation of hexagon edges and provide reducing of deformation heterogeneity. The rational shape and size of the ledges in the working area were determined; they provide regulated technical documentation for shape and sizes of a section, with reducing of deformation degree. Using a die with the ledges in the working area allows to obtain the required hexagonal section through a single pass, whereas in the case of using dies with flat working area, two or three passes with intermediate heat treatment operations are required. Verifi cation of the results of mathematical simulation was carried out by laboratorial testing, using approved testing machine and a full-scale experiment on the chain drawing machine.

The results of the research were used as the basis for development of the new technical solution (RF patent № 78102 «Die for production of polyhedral shaped sections».

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