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

Chul Jin

doi:10.3390/met9020207

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.

Highlights

Metal parts with complicated forms are generally manufactured with a mechanical working or casting process
Simulation result for forming into blocker is showed
A hot forging and warm forgingforging was designed to manufacture an umbrellaA process processcomprising comprising a hot forging and warm was designed to manufacture an shaped part with a high degree of shape difficulty

Summary

Introduction

Metal parts with complicated forms are generally manufactured with a mechanical working (multi-axis machining) or casting process. The casting process can make a part with complicated forms by implementing various casting methods such as die casting and sand casting depend on the price, shape, and mechanical properties of the product. In case of the parts for mechanical structure that require high mechanical properties, the part is manufactured with a sand casting process using ferrous iron or steel. In case of the part (transport equipment) which is used in the mechanical structure and even requires light weight, it cannot use ferrous material with a high density. A die casting process is used using non-ferrous materials such as aluminum or magnesium having a relatively low density. With a die casting method of aluminum or magnesium, it is almost not possible to manufacture a part having tensile strength more than 300 MPa

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Results

Conclusion