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Investigation on limited thickening ratio of upsetting with a controllable deformation zone

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Abstract

Upsetting with a controllable deformation zone (U-CDZ) is a newly developed sheet-bulk forming method to thicken the sidewall of a cup. It can avoid buckling on the inner surface of the tube with the help of a suitable counter force. The current studies about this process are all based on the case of double thickness ratio. This study focused on the forming procedure under larger thickening ratio and analyzed the material flow during the process. An improvement of the tool structure which is beneficial to the forming quality is proposed and verified. The radial extrusion process is used for the investigation of the thickening limitation of U-CDZ process based on the improvement. The critical flange length of radial extrusion process is considered as the reflection of the thickening limitation. The Latham-Cockcroft ductile fracture criterion is calibrated for the numerical simulation prediction of the critical flange length. The thickening limitation of U-CDZ process is obtained based on the experimental and simulation results. Minimum counterforce under different thickening ratio is acquired through numerical simulation, which is used for the establishment of process window in combination with critical thickening ratio.

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Acknowledgements

This research was supported by the National Natural Science Foundation of China (Grant 51575345) and the Fundamental Research Funds for the Central Universities of China.

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Authors and Affiliations

  1. Research Institute, Baoshan Iron & Steel Co., Ltd, Fujin Road 655, Shanghai, 201900, China

    Dongkai Xu

  2. State Key Laboratory of Development and Application Technology of Automotive Steels (BaoSteel), Fujin Road 655, Shanghai, 201900, China

    Dongkai Xu

  3. Institute of Forming Technology and Equipment, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200030, China

    Yin Zhu & Xincun Zhuang

  4. National Engineering Research Center of Die & Mold CAD, Shanghai Jiao Tong University, Shanghai, 200030, China

    Xincun Zhuang

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  1. Dongkai Xu
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  2. Yin Zhu
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Correspondence to Xincun Zhuang.

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Xu, D., Zhu, Y. & Zhuang, X. Investigation on limited thickening ratio of upsetting with a controllable deformation zone. Int J Adv Manuf Technol 125, 1701–1711 (2023). https://doi.org/10.1007/s00170-023-10826-2

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  • DOI: https://doi.org/10.1007/s00170-023-10826-2

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