Research and Optimization of Extrusion Tap Structure Based on Numerical Simulation and Experimental Analysis
Abstract
:1. Introduction
2. Working Mechanism of Tap
3. Tap machining Experiment
3.1. Construction of Experimental Platform
3.1.1. Extruded Tap and Workpiece
3.1.2. Measurement of Extrusion Torque and Temperature
3.2. Result of Experiment
3.2.1. Analysis of Extrusion Torque and Temperature
3.2.2. Analysis of Microstructure
3.2.3. Measurement of Hardness and Hardened Layer
4. Numerical Simulation of Tap Machining
4.1. Establishment and Validation of Model
4.2. Effect of Tap Structure on Extrusion Process
4.2.1. Analysis of Number of Edges
4.2.2. Analysis of Shovel Back
4.2.3. Analysis of Extrusion Cone
4.2.4. Analysis of Calibration Part
4.2.5. Analysis of Extrusion Cone Angle
4.3. Optimization of Tap Structure
4.3.1. Design of Orthogonal Test
4.3.2. Data Analysis of Orthogonal Test
5. Result and Discussion
5.1. Extrusion Torque and Temperature
5.2. Thread Height
5.3. Thread Hardness and Hardened Layer
6. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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C | Si | Mn | S | P | Cr | Mo | Fe |
---|---|---|---|---|---|---|---|
0.38 | 0.3 | 0.6 | 0.03 | 0.03 | 0.9 | 0.23 | Bal |
Young’s Modulus (GPa) | Poisson’s Ratio | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) |
---|---|---|---|---|
212 | 0.28 | 1080 | 930 | 12 |
Type | Parameter Value | Type | Parameter Value |
---|---|---|---|
Shovel back/(mm) | 0.6 | Bottom hole diameter/(mm) | 21.20 |
Extrusion cone angle/(°) | 6 | Hole depth/(mm) | 9 |
Extrusion cone/(mm) | 8 | Extrusion speed/(rmin−1) | 50 |
Calibration part/(mm) | 18 | Friction coefficient | 0.12 |
Tap large diameter/(mm) | 22.183 | Pitch/(mm) | 2 |
Level | A Edge | B Shovel Back (mm) | C Extrusion Cone (mm) | D Calibration Part (mm) |
---|---|---|---|---|
1 | 4 | 0.2 | 6 | 16 |
2 | 6 | 0.4 | 8 | 18 |
3 | 8 | 0.6 | 10 | 20 |
4 | 10 | 0.8 | 12 | 22 |
Number | A | B (mm) | C (mm) | D (mm) | Empty Column | Torque (N·M) | Temperature (°C) |
---|---|---|---|---|---|---|---|
1 | 4 | 0.2 | 6 | 16 | 5 | 123.25 | 105.27 |
2 | 4 | 0.4 | 8 | 18 | 6 | 139.47 | 105.12 |
3 | 4 | 0.6 | 10 | 20 | 7 | 137.34 | 96.88 |
4 | 4 | 0.8 | 12 | 22 | 8 | 136.24 | 94.13 |
5 | 6 | 0.2 | 8 | 20 | 8 | 143.92 | 100.33 |
6 | 6 | 0.4 | 6 | 22 | 7 | 129.88 | 91.02 |
7 | 6 | 0.6 | 12 | 16 | 6 | 128.68 | 77.57 |
8 | 6 | 0.8 | 10 | 18 | 5 | 117.07 | 68.11 |
9 | 8 | 0.2 | 10 | 22 | 6 | 138.63 | 119.23 |
10 | 8 | 0.4 | 12 | 20 | 5 | 126.87 | 107.59 |
11 | 8 | 0.6 | 6 | 18 | 8 | 102.19 | 65.01 |
12 | 8 | 0.8 | 8 | 16 | 7 | 95.28 | 62.48 |
13 | 10 | 0.2 | 12 | 18 | 7 | 177.84 | 136.13 |
14 | 10 | 0.4 | 10 | 16 | 8 | 151.74 | 134.88 |
15 | 10 | 0.6 | 8 | 22 | 5 | 155.08 | 104.71 |
16 | 10 | 0.8 | 6 | 20 | 6 | 132.24 | 82.77 |
Test Index | Factors | K1 | K2 | K3 | K4 | Range Value R |
---|---|---|---|---|---|---|
Extrusion torque (NM) | A | 134.08 | 145.91 | 121.89 | 124.74 | 130.57 |
B | 129.89 | 136.99 | 133.44 | 134.14 | 134.76 | |
C | 115.74 | 130.82 | 136.20 | 135.09 | 135.09 | |
D | 154.23 | 120.21 | 142.41 | 139.96 | 133.52 | |
Extrusion temperature (°C) | A | 100.35 | 115.24 | 86.02 | 95.05 | 96.42 |
B | 84.26 | 109.65 | 93.16 | 93.59 | 96.17 | |
C | 88.58 | 86.04 | 104.78 | 96.89 | 96.63 | |
D | 114.62 | 76.87 | 103.86 | 102.27 | 98.59 |
Test Index | Factors | Sum of Square of Deviations | Free Degree | Mean Square Error | F | P |
---|---|---|---|---|---|---|
Extrusion torque (NM) | A | 3032.94 | 3 | 1010.98 | 59.77 | 0.0036 |
B | 1400.19 | 466.73 | 27.59 | 0.0110 | ||
C | 885.61 | 295.20 | 17.45 | 0.0211 | ||
D | 485.71 | 161.90 | 9.57 | 0.0480 | ||
Error | 50.74 | 16.91 | ||||
Extrusion temperature (°C) | A | 2220.30 | 3 | 740.10 | 151.21 | 0.0009 |
B | 4071.83 | 1357.28 | 277.31 | 0.0004 | ||
C | 971.17 | 323.72 | 66.14 | 0.0031 | ||
D | 172.86 | 57.62 | 11.77 | 0.0363 | ||
Error | 14.68 | 4.89 |
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Tao, Y.; Wan, N.; Xu, D.; He, Q. Research and Optimization of Extrusion Tap Structure Based on Numerical Simulation and Experimental Analysis. Materials 2024, 17, 1891. https://doi.org/10.3390/ma17081891
Tao Y, Wan N, Xu D, He Q. Research and Optimization of Extrusion Tap Structure Based on Numerical Simulation and Experimental Analysis. Materials. 2024; 17(8):1891. https://doi.org/10.3390/ma17081891
Chicago/Turabian StyleTao, Yi, Nian Wan, Daoming Xu, and Qiang He. 2024. "Research and Optimization of Extrusion Tap Structure Based on Numerical Simulation and Experimental Analysis" Materials 17, no. 8: 1891. https://doi.org/10.3390/ma17081891