The metal flow in the bottom deep hole was studied through Deform finite ele-ment analysis when 2A10 aluminum alloy rivet sleeves were formed with different molds.The analysis of radial offset curves and stroke load curves show that chamfered male molds bears a smaller maximum load than unchamfered ones,effectively improving workpiece quality and mold life.The analysis was carried on the changes in equivalent stress-strain,metal flow,and stroke load during the head forming process with the optimized fully-chamfered male mold and the original one.The former mold leads to smoother metal flow,less bearing load,and less damage to the mold.With the former mold,the head forming is more reasonable and the quality is more uniform.
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