Optimizing Square Bellows Production: Externally Fixed Die Extrusion Process and FEA Insights

Abstract

This study investigates an advanced method for manufacturing square bellows through extrusion forming, with a focus on the design and performance of an externally fixed model. The aim of this work is to optimize the extrusion process for producing high-quality square bellows that meet the stringent requirements of various industrial applications, such as robotics and aerospace. Using Finite Element Analysis (FEA) simulations, we analyzed stress distributions and deformation patterns, identifying critical areas of stress concentration, particularly at the sharp corners of the bellows. The externally fixed design was selected over the internally fixed system due to its superior performance in terms of material flow and structural integrity. The simulation results indicate a reduction of stress concentration by 15% through the use of filleted edges and optimized die design. Mechanical and thermal cycling tests revealed that the bellows exhibited high fatigue resistance, enduring over 1,000,000 cycles without significant deformation, and showed minimal size changes under thermal expansion. Moreover, the incorporation of induction heating and precise hydraulic force control led to a 20% reduction in energy consumption and a 10% improvement in cooling efficiency. The proposed approach demonstrated superior accuracy, energy efficiency, and reliability compared to traditional stamping methods, making it a promising solution for the large-scale production of durable, high-performance square bellows.