Abstract
Aluminum suspension parts are usually formed by die forging process. This process shows high level of dies and material costs, because of the utilization of aluminum extrusion and forming in three sets of dies. Therefore the portion of the forging process is replaced with casting one to save the cost. This process, named 'cast/forging process', uses one set of dies and the workpiece made by casting. But reduction of the forging process decreases plastic deformation in the product. And it also decreases the mechanical properties. Therefore the effect of the forging process on the mechanical properties is investigated. The distribution of equivalent plastic strain in typical forging products is calculated by FEM. As a result, the forging die configuration and the workpiece shape suitable for the 'cast/forging process' are presented. One of suspension parts is also formed as an experiment. The static fracture strength in the trial parts is measured. Results obtained satisfy the requirements.
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