Simulation and Experiment of Manufacturing Process for Structural Aluminum Parts with Hard to Plastic Forming

Abstract

A process comprising a hot extrusion process and a warm forging process was designed to form an umbrella-shaped aluminum structural component with a high degree of difficulty for the plastic forming method. A circular cylindrical part was extruded with a hot extrusion process, and then an embossing part was produced with a warm forging process. The formability and the maximum load required for forming were then determined using a forming analysis program. The hot extrusion process was executed at 450 °C under the extrusion speed at 6 mm/s, while the warm forging process was executed at 260 °C under the forging speed at 150 mm/s. The simulation results showed that the load required for hot extrusion was 1019 ton, while the load required for the warm forging was 534 ton. The umbrella-shaped part was manufactured by using a 1600 ton capacity press. The graphite lubricant was coated on the mold as well as the material. A forming experiment was performed under the same condition with the simulation condition. The portion where extrusion was done became elliptical with the α-Al phase elongated towards extrusion direction. Whereas, the α-Al phase became circular in the forged portion. The tensile strength value was found as 345 MPa, while elongation rate was 12%. Meanwhile, Vickers hardness value at the extruded portion was 105 HV, and it was 110 HV at the forged portion.