Large Aluminum Alloy Beam Frame Forging Forming Process Simulation And Experimental Studies

It is important bearing part on the aircraft of the large aluminum beam with ribs on it, of which the forming load is very large, and the requirements are very strict. It becomes a very important topic of forming so large a part on the equipment with insufficient pressure and to ensure the quality.According to the manufacturing need of a certain large aluminum beam frame,the theoretical analysis combined with the numerical simulation to design the preforge shape and the forming process,and then take the experiment which show that:(1) Based on the forging technology and the forging shape,a reasonable pre-forging shape is designed, The forming process is divided into three stages as upsetting, filling and packing. The load pressure of the H shaped cross section preforging reduce by 21.8% compared with the square cross-section preforging under the same process prameters and can effectively avoid the defects as rib penetration to assure the good quality of the forging.(2) Of the isotherm forging under 800MN forging process parameters, simulation is carried out and the results show that the forging material is greatly influenced by the recovery and dynamic recrystallization when the loading speed under 1mm/s, the plasticity increase but not fully deformated; when the loading speed exceed 1mm/s, the hardedign is more obvious,and the forming load increase dramatically; It is more preferable to be loaded with the loading peed of lmm/s. The influence of the forming load by the friction is linear:the forming load increase with the increase of the friction, it is better to take lower friciton to be formed under the load of 800MN,ensure that the friction is about 0.1. The temperature of the dies is the key factor of the forming plasticity and the reduction of foming load. It is preferable to take the isothermal forming with the temperature of 450℃.(3) It is a great problem that the load of large frame is very high and very difficult to precisely forged with conventional forging method on the hydraylic press that the load is insufficient, to solve the problem, research is carried out on the part loading program, and it is proposed of the part loading program under the isothermal loading prameters above mentioned.The result of the Program show that the reasonable division can improve the foming quality and reduce the forming load, the forming load of each top die doesn't exceed 300MN, which can ensure that the forming load under the hydraulic of 300MN pressure by dividing the loading area into three and two passed. It is the better prameters of the first deforming rate is 40%and 15%in the second.(4) Lead is made as the experimental materials to carry out the scale experiment, and the experiment results is identical with the simulation result:the well designed pre-forming forgings flow equally, and is well filled with the flash distributes uniformily;the forging not preformed deforms inhomogeneously significantly. Because of the large differences in the resistance different parts of forging, the flash uneven distribution along the contour; The role of the resistance cabin is very obvious, it is suggested that the resistance cabin is necessary in the actual forging to ensure good filling and dense tissue.