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A Combined Radial Forging-Forward Extrusion Forming Process of Alternator Poles

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Abstract

A combined radial forging-forward extrusion forming process of alternator poles is proposed based on an analysis of the structure of alternator poles as well as the forming die sets. First, a thick-bottom base of the alternator poles is obtained through radial forging. The middle boss and claw teeth are then formed through forward extrusion. A 3D coupled thermomechanical finite element model is employed. Billet deformation, metal flow, and forming load are obtained. The results show that the middle boss cavity is filled earlier and the process is no longer simultaneous extrusion during the second forming step. Then, the forming load increases sharply. An improved process that controls the metal flow in the middle boss cavity and aids in pushing the metal into the corners of the claw teeth cavity is proposed. The middle boss and claw teeth cavities can be filled simultaneously. The sharp increase of the forming load in the final forming stage is avoided. Simulative and experimental results show that the improved process can considerably reduce the final forming load to form a well-shaped product.

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Acknowledgments

This work is supported by the National Natural Science Foundation of China (Grant No. 50975222), the Natural Science Foundation of Education Department of Shaanxi Provincial Government (Grant No. 11JK0801), and the Natural Science Basic Research Plan in Shaanxi Province of China (Program No. 2012JM7019).

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Authors and Affiliations

  1. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, 710049, China

    Cheng Yang & Shengdun Zhao

  2. School of Metallurgical Engineering, Xi’an University of Architecture and Technology, Xi’an, 710049, China

    Cheng Yang & Jianjun Zhang

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  1. Cheng Yang
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  2. Shengdun Zhao
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  3. Jianjun Zhang
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Correspondence to Cheng Yang.

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Yang, C., Zhao, S. & Zhang, J. A Combined Radial Forging-Forward Extrusion Forming Process of Alternator Poles. J. of Materi Eng and Perform 23, 108–114 (2014). https://doi.org/10.1007/s11665-013-0733-6

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  • DOI: https://doi.org/10.1007/s11665-013-0733-6

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