Cabin Component Extrusion Die for Uniform Thin-Wall Forming
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Solution Overview
Problem
Current molding technologies for large thin-walled cabin components, such as reverse extrusion and multi-pass spin forming, result in uneven strain and crystal grain distribution, leading to defects like damage and fracture at the opening, and low yield and material utilization rates, especially when using light alloys like aluminum and magnesium.
Innovation Solution
An extrusion forming die comprising an upper die assembly with an extrusion punch and a combined concave die featuring an M-shaped outer concave die and a W-shaped inner concave die, forming a rotary extrusion die cavity with a W-shaped longitudinal section, which guides metal extrusion to reduce strain differences and enhance back pressure, ensuring uniform crystal grain distribution and improved mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reverse extrusion and machining processes are used for manufacturing cabin components, then production efficiency is high and operation is convenient, but the deformation is small resulting in lower mechanical performance
Solution Approach 1:
The patent employs dynamic multi-pass spin forming process where the forming tool rotates and applies progressive deformation in multiple passes. This dynamic approach enables large total deformation to be accumulated while maintaining high production efficiency, resolving the contradiction between limited deformation in single-pass extrusion and the need for high mechanical performance
Solution Approach 2:
The multi-pass spin forming process applies continuous plastic deformation through multiple sequential passes without interrupting the forming action. Each pass contributes to cumulative deformation, ensuring the material continuously undergoes strain hardening and grain refinement, thereby achieving high mechanical performance while maintaining production efficiency
2Manufacturing precision
If upsetting, punching, reaming for many times and machining processes are used for large thin-walled cabin components, then the components can be manufactured, but the production process is long and manufacturing costs increase
Solution Approach 1:
The patent combines multiple traditional processes (upsetting, punching, reaming) into a single integrated multi-pass spin forming operation. The forming tool performs all necessary shaping, hole creation, and surface finishing in one continuous process, eliminating the need for separate machining operations and significantly reducing production process length while maintaining manufacturing precision
Solution Approach 2:
The spin forming tool is designed with multi-functional capabilities to perform various operations including material displacement, hole formation, and surface shaping simultaneously. This universal tool replaces multiple specialized tools and processes, reducing the overall production process length while achieving the required component geometry accuracy
3Shape
If repeated extrusion processes are used for manufacturing cabin components, then the components can be formed, but heat is generated that affects mechanical performance and results in poor consistency of product performance
Solution Approach 1:
The multi-pass spin forming process applies periodic deformation cycles with controlled intervals between passes. This periodic action allows for controlled strain accumulation and heat dissipation, preventing excessive temperature rise that would compromise mechanical performance consistency while still achieving the required component geometry through cumulative deformation
4Shape
If multi-pass spin forming technology is used for aluminum alloy cabin components, then large thin-walled components can be manufactured, but it is easy to cause cracking of magnesium alloy due to harsh molding conditions resulting in low yield
Solution Approach 1:
The patent applies local quality control by adjusting forming parameters specifically for different material types. For magnesium alloys, the multi-pass process uses gentler deformation conditions with controlled strain rates and intermediate annealing, while aluminum alloys can withstand more aggressive forming. This localized parameter optimization prevents cracking in magnesium alloys while maintaining the ability to form large thin-walled geometries
Solution Approach 2:
The patent changes key process parameters including strain rate, temperature, and pass intervals based on material properties. For magnesium alloys, lower strain rates and controlled temperatures are used to prevent cracking, while the multi-pass approach allows gradual deformation accumulation. This parameter adaptation enables successful manufacturing of large thin-walled components across different light alloys with high yield
5Shape
If multi-pass spin forming technology is used for cabin components, then large thin-walled components can be manufactured, but it is easy to cause corrugation and other defects in the molding process making the surface quality poor
Solution Approach 1:
The patent applies partial deformation in each pass rather than attempting complete forming in one operation. By distributing the total deformation across multiple passes with controlled strain per pass, the process avoids excessive localized deformation that causes corrugation. Each pass applies just enough deformation to progress toward the final geometry while maintaining surface quality, and the cumulative effect achieves the required component geometry
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively avoids damage and fracture at the opening of cabin components, enhances yield and material utilization, and improves mechanical performance by achieving uniform crystal grain distribution and equivalent plastic strain, thus optimizing the manufacturing process for large thin-walled cabin components.
Implementation Method 1
make the entire metal subjected to more uniform equivalent plastic strain
Data Source
AI summary
The present disclosure provides an extrusion forming die for a cabin component. The extrusion forming die for a cabin component comprises an upper die assembly, a lower die assembly and a combined concave die. The upper die assembly comprises an extrusion punch (3), and the combined concave die comprises an M-shaped outer concave die (4) having a hollow cavity matched with the extrusion punch (3), and a W-shaped inner concave die (5) having a rotary cavity. The W-shaped inner concave die (5) is arranged in the rotary cavity of the M-shaped outer concave die (4) in a matched manner, and the rotary cavity and the hollow cavity are matched to form a rotary extrusion die cavity (18) with a W-shaped longitudinal section.