Die structure optimization for eliminating premature folding of sidewall upsetting with a controllable deformation zone
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Upsetting with a controllable deformation zone is a newly developed sheet-bulk forming method to thicken the sidewall of a cup. Compared with conventional upsetting, this new method can eliminate the limitation of the slenderness ratio and improve forming quality. However, the risk of premature folding on the outer surface of the thickened cup cannot be ignored. Thus, this study proposes an enhanced die structure to suppress the risk of premature folding. In order to evaluate premature folding, an estimate index is provided. Design of experiments and analysis of variance are adopted to establish a regression model between process parameters and the estimate index. The response surface and contour plot can then be created on the basis of the regression model. With a carefully determined critical value of the estimate index, an optimized die structure can be obtained, for which the risk of premature folding is experimentally proven to be eliminated.
KeywordsUpsetting with controllable deformation zone Die structure optimization Premature folding Response surface Estimate index
This research was supported by the National Natural Science Foundation of China (Grants 51575345 and 51875351), the National Science & Technology Major Project of China (Grant No.2018ZX04024001-004), and the Fundamental Research Funds for the Central Universities of China.
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