Abstract: Three kinds of defects which affect the boss height during the forming process were analyzed. Based on the analysis, the concept of effective volume rate was put forward as index. The orthogonal experimental analysis on the influencing factors of forming result was carried out with the use of numerical simulation and physical experiment to find out the key influence factors. A further study was made to find how the key factors influence the high boss forming results. The research results provide guidelines for the process design and die structure optimization.

Key words: sheet metal extrusion, high boss forming, orthogonal experimental method, optimization