Abstract
Press forging is a process for forming bosses with thin sheet metals. In this work, press forging has been applied to manufacture magnesium-alloy notebook computer case with complex geometry, such as sidewalls, bosses, and hooks. Forming characteristics, influence of process parameters on metal flow, and forming defect are investigated by using both experimental approach and the finite element method (FEM). The results show that the sidewalls, bosses, and hooks of the case can be formed synchronously. It is found that the sidewalls are not uniformly formed, and the formability of the bosses varies with the position and geometry. Due to the rotating material flow in hook cavity, material dead zone appears at the root area of the hook. The methods of increasing the resistance of material flow outwards can be used to prevent the defect in hook forming. The present study indicates that magnesium-alloy notebook case with complex geometry can be produced by press forging, and it provides a promising alternative to the electronic industry in the application of press forging process.
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