Processing design and optimization on rotary forging of thin-walled structure

Abstract

The aluminum alloy cellphone case is a complex component, which is difficult to be produced through conventional integral forging owing to its thin wall with variable thickness and tiny bosses. This paper utilizes an incremental cold rotary forging method to produce cellphone case and conducts researches on cold rotary forging of cellphone case under linear movement of oscillating die. Firstly, the oscillating die under linear movement is theoretically designed. The intervening models between oscillating die and cellphone case are also established and correspondingly, the intervening areas of oscillating die and cellphone case are amended so as to guarantee the forming quality. Secondly, the process conditions are optimized through analyzing the metal flow laws when the oscillating die performs linear movement. Thirdly, physical experiments are utilized to prove the feasibility of cold rotary forging of cellphone case under linear movement of oscillating die.