Research on Optimal Design of Multi-DoF Forming Process for High-Ribbed Ring-Groove Components

Aiming at the technical challenges in the Multi-DoF forming of 20CrMnTi high-ribbed ring-groove components, including complex metal flow behavior that easily causes under-filling defects and complicated die stress states prone to die failure, this paper proposes an optimal design method for the Multi-DoF forming process of high-ribbed ring-groove components. The influence mechanism of different blank sizes on metal flow and component filling effect is systematically investigated, and three typical metal flow modes are identified. Furthermore, a die stress optimization method for Multi-DoF forming is proposed. Research results show that, compared with the outward-to-inward and inward-to-outward metal flow modes, the metal flow under the symmetric inward–outward flow metal flow mode is more balanced, ensuring that the two high ribs can be fully formed. Additionally, changing the blank size can balance the forces on both sides of the die boss, thus significantly reducing the risk of die cracking caused by stress concentration. On the basis of the above research results, experimental tests are conducted, and the high-ribbed ring-groove components achieve full forming quality without die failure, which verifies the feasibility and effectiveness of the process optimization design method proposed in this paper.