Research On The Cold Upsetting-extruding Technology For Complex Cup-shaped Aluminum Alloy Parts With Thin Walled Section

In the forging productions of the aero engine Intake Diversion Cone part with a cup-shaped profile, the forging part is always designed as a cylindrical free forging part according to the forging factory’s actual capacity. So the machining allowance of the forging part is so large to affect the processing cycle significantly. The very low utilization rate of material can also satisfy the demand of the lean manufacturing.For all this, the cold upsetting-extruding technology for the Intake Diversion Cone part is researched further. Firstly, according to the structural characteristics of the part and the factory’s forging and mechanical processing level, the forging part is designed to be similar with the part’s profile. This can make the utilization rate of raw material increased from less than4%to13.5%, about75%raw material can be economized compared with free forging. Secondly, a numerical model of the forging part is constructed, and the cold upsetting-extruding technology and die designing are checked by simulation. Thirdly, based on a series of cold forging tests for2A70Aluminum alloy, the material softening parameters, cold forging parameters and heat treatment parameters are figured out, the forging process route can be obtained, that is, cutting→softening→cold forging→heat treatment. Finally, through field experiments the forging part is manufactured, and the reasonableness of the processing technology is proved by machining.The research results show that the process route proposed can satisfy the demand of the forging production for Intake Diversion Cone forging part, the machining allowance of the forging is lowered, the raw material is saved, the processing cycle is shorten and the needs of the lean manufacturing can be met too.