Optimization And Numerical Analysis Of Forging Process Of Aluminum Alloy Control Arm

As one of the core components in the automotive suspension system,the control arm has high requirements on mechanical properties such as stiffness,strength,impact toughness and fatigue strength.With the lightweight design requirements of contemporary automobiles,the 6082 aluminum alloy has gradually become one of the commonly used materials for control arms.The shape of the aluminum alloy control arm is complicated,and it is easy to have defects such as folding,coarse crystal,filling,and eddy current during the forming process.The main purpose of this paper is to develop a reasonable aluminum alloy control arm forging process.The forging defects are mainly avoided from the aspects of forging process parameters and mold optimization.In this paper,the research method of finite element analysis and experiment is used to study the forming law of forging and optimize the forming process.Through the analysis of temperature field,velocity field and stress field,the folding defects which may occur in the pre-forging process are predicted,and the folding defects are improved by modifying the mold.The influence of forming temperature and mold temperature on the pre-forging forming effect is obtained.law.It is beneficial to reduce the forming load by appropriately increasing the forming temperature without causing the final forging temperature to be too high.Properly increasing the mold temperature can make the forging temperature distribution more uniform and reduce the equivalent stress of the forging to improve the forming effect.The grain refinement rule of 6082 aluminum alloy was studied by numerical simulation.It was found that the average grain size increased first and then decreased with the increase of temperature in the temperature range of 400 °C-550 °C.The average crystal at 450 °C The particle size is the smallest.Excellent lubrication facilitates grain refinement during forging.According to this law,the final forging temperature and friction conditions which are favorable for grain refinement are selected.Experimental studies on the coarse crystal defects existing in forgings have found that the unevenness of deformation and the speed difference of metal flow are the main causes of coarse crystals.Through repeated numerical simulation and forging experimental research,this paper proves the effectiveness of the above defect improvement measures.The rationality of the forging process parameters was verified,and finally the qualified forged aluminum alloy control arm was obtained.