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<p>To address the challenge of rib filling in large-scale ribbed thick plate components (LSRTPCs), this study adopts a combined experimental and finite element (FE) simulation approach. The reliability of FE simulations was evaluated by comparing the rib groove filling effect of LSRTPC, from which variations in plate thickness lead to differences in the rib filling effect. The analysis based on characteristic models demonstrates that thinner billets exhibit faster material flow during the forming process, resulting in higher material filling rates under the same forming force. The velocity field analysis based on energy theory and FE simulations indicates that as billet thickness increases, shear power consumption within the effective deformation area rises, whilst the high-hydrostatic-stress area outside the effective deformation area expands. These two factors collectively result in an increase in forming force. A compatible deformation process combining local extrusion and integral extrusion was proposed, and forming experiments were conducted. Results show a significant improvement in the forming quality of the rib, achieving controllable metal flow under low-forming-force conditions. This work provides technical support for defect suppression and low-energy manufacturing of LSRTPCs in extrusion forming.</p>

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The causes of the high extrusion forming force in ribbed thick plates and the solutions

  • 期刊论文

  • 发表日期：

    2025年2月3日

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  • Ang Wu,
  • Zhimin Zhang,
  • Guojun Li,
  • Jian Xu

摘要

To address the challenge of rib filling in large-scale ribbed thick plate components (LSRTPCs), this study adopts a combined experimental and finite element (FE) simulation approach. The reliability of FE simulations was evaluated by comparing the rib groove filling effect of LSRTPC, from which variations in plate thickness lead to differences in the rib filling effect. The analysis based on characteristic models demonstrates that thinner billets exhibit faster material flow during the forming process, resulting in higher material filling rates under the same forming force. The velocity field analysis based on energy theory and FE simulations indicates that as billet thickness increases, shear power consumption within the effective deformation area rises, whilst the high-hydrostatic-stress area outside the effective deformation area expands. These two factors collectively result in an increase in forming force. A compatible deformation process combining local extrusion and integral extrusion was proposed, and forming experiments were conducted. Results show a significant improvement in the forming quality of the rib, achieving controllable metal flow under low-forming-force conditions. This work provides technical support for defect suppression and low-energy manufacturing of LSRTPCs in extrusion forming.