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The research was financed in the framework of the project: New metal forming technique
for producing flanged hollow parts for the mining industry, No. LIDER/1/0003/L-9/17/NCBR/2018.
Total cost of the Project: 1197000 PLN. The project is financed by the National Centre for Research
and Development under the 9th edition of the LIDER Programme.
This paper presents a new method for forming hollow flanged products. The method
involves extrusion with the use of a sleeve moving in the opposite direction to that of the punch.
A tube with a constant hole diameter and two different outside diameters, made of aluminum
alloy EN AW 6060 was used as a material. Numerical calculations were performed using Deform
2D/3D. Experiments were conducted on the PYE 160SS hydraulic press equipped with a specially
designed device in which the punch is driven by the press slide while the moveable sleeve is driven
by two hydraulic servomotors. Both numerical simulations and experiments were conducted under
cold forming conditions. The aim of this study was to determine the effect of selected parameters
(flange diameter, height of the cavity in the moveable sleeve, and the chamfer angle between the
regions with different outside diameters on the workpiece and in the moveable sleeve cavity) on the
stability of the extrusion process. Results were then used to undertake detailed comparative analyses
of underfill, flange heights, and flange flank inclination angles. Findings of the analyses served as a
basis for drawing conclusions regarding the effect of the analyzed parameters on the investigated