DEVELOPMENT OF THE METHOD OF GAS MOLDING WITH BACK PRESSURE AND CREATION OF THE EQUIPMENT FOR ITS IMPLEMENTATION

Technological machines and equipment used in the food, chemical and other industries, are produced in relatively small batches.  These machines and equipment contains a large number of sheet metal  parts of complex shape having a relatively small height. Traditional methods of stamping are not sufficiently effective for the production  of such parts in small batch production. For the efficient production  of such parts there is a new method for sheet metal forming – forming  gas backpressure. The essence of this method lies in the fact that the  unilateral influence of the hot gas sheet billet is heated to a predetermined temperature, and then is formed. Thus to limit the deformation  of the billet during its heating on the opposite side it creates pressure  the influence of compressed air. As the hot gas a combustion gas-air  mixtures is used. Due to the heating of the billet up to the temperature  range of the warm hot treatment this method provides obtaining of  complex-shaped parts in one work step, which significantly reduces  the cost of production. Studying the heating process of the billet set  up, the pattern of temperature change in time was determined, which  ensures the controllability of the process. The expressions for determining the gas pressure were derived, ensuring the implementation of  the molding process. To implement this method of molding installation for a gas forming a pressure is designed and developed containing device for forming the gas and fuel delivery and control. Using it  the experimental studies were made for the process of forming several  types of components: spherical bottoms, cylindrical part with a flange  part with a surface of double curvature, parts with small relief panels  of the heat exchanger with a helical channel. At the same time, optimal technologi cal regimes of gas molding are determined, ensuring  the obtaining of good quality parts. Experimental studies have shown  that this method of forming allows to obtain parts of complex shape in  one work step using a relatively simple stereotyped equipment. Due to  this application of the molding method can provide considerable cost  savings in parts production, especially in small-scale production. This  method is useful for forming steel parts with thickness up to 1.5  mm  and of parts made of nonferrous alloys with the thickness up to of  2  –  3  mm.

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