Study On The Forging Process And Quality Control Of Aluminum Alloy Wheel

Compared with other traditional methods such as casting and welding,the forged aluminum alloy wheels have uniform fine grains and good mechanical properties,occupying irreplaceable positions in the use of load-bearing vehicles such as commercial vehicles.The aluminum alloy wheel has a large size,a relatively complex shape,and a high processing precision.The setting of the forging process parameters and the rationality of the mold design grea tly affect the forming.Domestic research on forged aluminum alloy wheels started late and existing research results are mostly kept in secret.Based on the above background,this paper takes 6061 for ged aluminum alloy wheels as research object.The main research contents are:(1)Based on the mastery of the use characteristics and processing characteristics of forged aluminum alloy wheels,according to forging experience and mold theory,the “pre-forging-final forging-spinning forging process flow was confirmed;(2)Using three-dimensional modeling software to establish three-dimensional solid modeling of blanks,pre-forging and final forging dies.Based on the rigid plastic finite element method,the model was introduced into the finite element numerical simulation software AFDEX.Three-dimensional thermo-mechanical coupling simulations were performed on the pre-forging and final forging processes,the forming characteristics such as metal flow trend,stress-strain distribution,and stroke-load curve during the forging process were obtained.(3)Based on the analysis of simulation results,to predict the possible defects in the actual forging,from the mechanism analysis,put forward an effective optimization program;(4)To verify the feasibility of implementation of the forging process and the effectiveness of the optimization scheme,the two programs before and after optimization were being put into operation;(5)The problems of the lubrication and forging temperatures which are difficult to predict in the early stage in the trial production process were observed and discussed,and based on their characteristics,the practical solutions were proposed;(6)Test the products obtained after the trial production from the metallographic structure and mechanical properties to observe whether the product meets the target requirements.The research results are as follows:(1)Forging process flow of "pre-forging-final forging-spinning" can produce the aluminum alloy wheels that meet the standards,and the process flow is feasibility;(2)Pre-forging and final forging process parameters were determined as: the mold temperature is 300 °C,the billet temperature is 450 °C;(3)To forged aluminum alloy wheels,the inappropriate design of the rounded corners of the mold convex easy to make the edge of the wheel spokes and rims at the junction of the metal fl ow back trend.It has been verified that when the pre-forging upper die set is not provided with raised fillets and the final forging upper die convex fillet radius is R6 mm,the occurrence of the defect can be effectively mitigated;(4)The spoke part of the wheel is subject to greater deformation,where the grains are difficult to distinguish and exhibit fibrous striations;the rim area is affected by the subsequent spinning process,where the grains are uniform and elongated;(5)Forged aluminum alloy wheels generally have relatively uniform organization and there is no coarse grain;(6)For the tensile strength and yield strength,the rim of the wheel is lower than the spoke portion;and in the aspect of the elongation,the rim is affected by the spinning process and has better toughness,this feature can better meet the characteristics of the car wheels in the driving process.