Moscow Polytechnic University (Moscow, Russia):

Yu. G. Kalpin, Dr. Eng., Prof., Dept. of Metal Forming and Additive Technologies, e-mail: kalpin@inbox.ru
Yu. K. Filippov, Dr. Eng., Prof., Dept. of Metal Forming and Additive Technologies, e-mail: yulianf@mail.ru
S. A. Tipalin, Cand. Eng., Associate Prof., Dept. of Metal Forming and Additive Technologies, e-mail: tsa_mami@mail.ru
A. G. Zaitsev, Post-Graduate, Dept. of Metal Forming and Additive Technologies, e-mail: Anton.Zaitsev@gmail.com

The process of extrusion of a hollow part such as an eccentric of a high-pressure pump of a diesel engine of an automobile is being investigated. A theoretical analysis of the deformation of the operations of the pre-landing of the workpiece in the tool with beveled end surfaces of the matrix and the punch is performed. With minimal assumptions, the kinematic parameters of the eccentric landing process with beveled surfaces were obtained. The analytical dependence for the force arising in this process is given. For comparison, a theoretical analysis of the process of direct extrusion on an eccentric head located on the rod is performed. The flow rates of the material in the workpiece and the force parameters of the process during extrusion are determined. Shows graphs showing the area of extrusion or landing during the stamping of parts depending on the magnitude of the strain intensity on the eccentricity and size of the deformable part. Charts are for three different steel grades. The form of dependence for different materials has a similar character, but differs in its size. It is confirmed that shaping the flange with an eccentricity of the hollow part during the landing is preferable to the extrusion process. This is justified by analytical calculations using the power balance method. The given data allow reasonably choosing the method of cold forging of a part with flange eccentricity depending on the force of the tool impact on the workpiece. The modeling of the main shaping operations in the QForm-3D system, confi rming the efficiency of the proposed technological process of cold volumetric stamping of a blank with an eccentric flange, has been carried out. The initial data and simulation results are presented. A comparison is made of the results of the energy-power characteristics obtained by analytical calculations and experimentally.

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