Application of numerical methods for the aluminum casting/forging process

Abstract

Recently, the significance of the hybrid process for manufacturing automobile parts is being noted. The authors are engaged in the development of one of these hybrid processes, the aluminum casting/forging process. This new process is a way of forging a workpiece preformed by casting into the final shape prior to machining. Low cost and good mechanical properties are expected. Some experiments show that eliminating fine pores in casting is very important to obtain high strength and elongation. So, the authors simulate the changes in the relative density of castings during forging, much like analyzing powder-forging, by using the deform, FEM program by Battelle. This agrees well with actual experiment results. Now, this simulation helps the authors design the shape of castings as a perform for casting/forging and enables them to obtain products without pores after forging at a minimum cost.