Improving the productivity of the pipe extrusion process based on computer modeling

Abstract

The paper presents the results of the study of the method of direct pressing of pipes using a moving and fixed needle in order to determine the rational design of the pressing tool, which ensures increased efficiency of the technological process. The analysis of the influence of the geometry of the matrix funnel on the nature of the metal flow, the stress-strain state, the energy-power characteristics and the conditions for forming pipe blanks was carried out. To compare different pressing schemes, computer modeling was used in the Deform 2D/3D software package, which made it possible to study the process of pressing the aluminum alloy AD1 through flat, conical and curved (concave) profiles of the matrices. It was established that the shape of the matrix funnel significantly affects the magnitude of the maximum pressing force, the uniformity of the plastic flow of the metal, the distribution of contact stresses and the intensity of the deformation tool. The most effective were the dies with a profile formed along the sliding line, which separates the deformation zone from the "dead" zone, which leads to minimal energy consumption, a more favorable distribution of deformations and increased process stability compared to pressing pipes through traditional flat and conical dies. The tool wear was also evaluated using the Reyer-Archard-Khrushchev model, which made it possible to determine the influence of contact conditions on the durability of the press tool. The results obtained confirm the feasibility of using profiled die funnels during direct pressing of pipes and can be used to optimize the design of the press tool, reduce the energy intensity of the process, increase the resource of technological equipment and ensure stable production of pipes of a given assortment.