Abstract
Disk-like parts with both thin web plates and thick rims are widely applied in automotive and aviation industries. These parts are usually made via welding and machining, which often lead to low material utilization, high energy consumption and low product performance. Therefore, a new sheet blank rotary forging process for thickening the rims of disc-like sheet blanks with uniform thicknesses was proposed in this paper. Based on FEA and experiments, both the effects of main defects and process parameters on forming were investigated. Besides, by considering the flow line distribution in formed parts, the material deformation feature in the forming process was analyzed. The results showed that the deformation process can be divided into four stages, and there are mainly four kinds of defects occurring during forming. Materials in the outer side of rim flows not only in the radial direction but also in the tangential direction.
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