A study on aluminum metal matrix preforms forging into double-hub flange

Abstract

The present article presents investigation of deformation characteristics during forging (closed-die) of SiCp AMC. The preform (cylindrical) fabricated via liquid metal stir casting manufacturing route were located centrally in closed-die set with respect to its axis and forged into axi-symmetric double-hub flange component. Initial experiments were conducted to examine the mechanical characterization of the AMC preforms under consideration, which also included investigations into interfacial frictional conditions and stress-strain behaviour of the AMC material. Under a controlled die-travel till the die corners were filled completely, during forging of the preforms, corresponding height reductions and die loads were recorded. The complete deformations were considered in two stages, i.e. free barreling and constrained distortion stages. The theoretical expressions (generalized using ‘Upper Bound’ technique) for strain rates, velocity field, various energy dissipations along with average die loads for all the deformation modes considered in the present study were formulated. The variation in die loads, die cavity fills and energy dissipations due to the effect of preform aspect ratio and die velocity were critically examined and experimentally compared the results.