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Influence of unidirectional loading pusher head structure on the deformation law of bionic egg-shaped shells in internal high-pressure bulging

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Abstract

A solid particle medium flexible bulging technology is proposed to solve the problems of low forming precision, poor stability, and uneven deformation that may occur when processing bionic egg-shaped shells by the traditional bulging process. By optimizing the mold parameters, such as the angle and height of the pusher head, the flow characteristics of the granular material are improved, resulting in improved machining accuracy and surface quality when forming egg-shaped plastic shells. In this paper, it utilized a ø0.8–1-mm yttria-stabilized zirconia ceramic bead to serve as a pressure-transfer medium during the granular media forming process. Several different shapes of pusher heads with cone angles of 45°, 60°, 75°, and 90° and heights of 10 mm, 25 mm, and 40 mm were designed. The numerical model of simulation was verified by the analysis of strain inhomogeneity coefficient, and the maximum thinning rate at the bulging curve apex of the egg-shaped test was measured and calculated. The results show that the maximum thinning rate at the bulging curve apex is the largest for the pusher head with 45° cone angle and 25 mm height, and the strain distribution is the most uniform and the bulging effect is the best. The study shows that it can effectively improve the strain distribution uniformity and thickness distribution during the egg-shaped shell forming process by optimizing the process parameters of the pusher head shape, thus it improves the plastic deformation machining accuracy of the bionic egg-shaped tube test piece.

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Funding

All the experiments were financed and supported by the National Natural Science Foundation of China (52205372) and the pre-research funds project in Zhangjiagang city (ZKCXY2131).

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  1. School of Mechanical Engineering, Jiangsu University of Science and Technology, Zhenjiang, 212003, China

    Zhiying Sun, Mingting Shen, Zhengxian Shi & Huiming Cheng

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  1. Zhiying Sun
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  2. Mingting Shen
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  3. Zhengxian Shi
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Correspondence to Zhiying Sun.

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Sun, Z., Shen, M., Shi, Z. et al. Influence of unidirectional loading pusher head structure on the deformation law of bionic egg-shaped shells in internal high-pressure bulging. Int J Adv Manuf Technol 130, 5219–5232 (2024). https://doi.org/10.1007/s00170-024-13036-6

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