Forming method of deep cavity thin-walled metal component with extremely small fillet radius

A method for forming a cavity metal component with fillet radius, comprising the following steps:

• step 1. according to analysis of the cavity depth, cross section shape and dimension of a component, respectively formulating forming process paths of a global cavity and a local transition fillet;
• multi-stage deep drawing the global cavity by means of a rigid die, and locally extruding the local fillet by means of an extrusion/pushing die;
• step 2. in combination with step 1, through theoretical analysis, determining multi-stage deep drawing part and final part key dimension parameters n, R, h, r, and process parameters m, d, wherein the number of straight wall edges of sidewalls is n, each of the deep drawing bottom and side wall fillet radii is R, the cavity depth is h, the number of deep drawing passes is m, an extrusion amount for extruding fillets is d, and the radius of the extruded fillet is r;
• creating a multivariate function ƒ(R, m, n, r, d)=0, assigning R, n, m to obtain a corresponding relationship between the extrusion amount de for extruding small fillets and the radius r of the extruded fillet;
• through numerical simulation, analyzing global cavity deep drawing and local fillet extrusion, and optimizing a matching relationship between process parameters m, d, to guarantee that both multi-pass deep drawing and fillet extrusion are performed;
• step 3. designing and machining die tooling used for performing global cavity deep drawing and local fillet extrusion according to the deep drawing part and final part key dimension parameters n, R, h, r and optimized process parameters m, d, which are determined in step 2, and determining an overall scheme of the die tooling and device parameter requirements;
• step 4. globally deep drawing an original metal slab according to the process parameters set in step 2 by means of the global cavity deep drawing die designed and machined in step 3, obtaining the cavity depth, cross section shape and the final part key dimension which are determined in step 2 and are consistent with a final cavity metal component, each of the obtained sidewall and bottom fillet radii being 2.0 to 4.0 times of the fillet radius required for a final metal component;
• step 5. further extruding global cavity obtained in step 4 according to the process parameters set in step 2 by means of the die tooling in step 3, further reducing the sidewall and bottom fillet radii to the fillet dimension (1.0-3.0 times of wall thickness);
• and step 6. performing flange edge cutting or sidewall punching on the global cavity, which is obtained in step 5, obtaining the final cavity metal component with fillet radius.