Study On Welding And Forging Composite Forming Of Aluminum Alloy Wheel Rim For Heavy Vehicles

The purpose of this article is to find a new manufacturing process of aluminum alloy wheel which is used on heavy vehicles, in order to improve product performance and productivity, reduce the costs and energy consumptions. Take the typical rim (8.5B-20) as study background, choose the 2219 aluminum alloy sheet metal, study the forming process and design the die.First of all, analyze the existing production methods, and give a new idea of forming, that is, welded a piece of sheet metal after rolled into a round, and then flanged. Through process design and calculations, the vacuum electron beam welding was determined as welding method. The forming process is as follows: tailor the sheet metal→rolling and welding→necking→flanging bottom→bulging and flanging perform→flaring.We selected the parameters of vacuum electron beam welding method through the experiment as follows: the welding voltage is 45KV; the welding current is 240mA; the focusing current is 1518mA, a focal point is 5mm under the surface of the aluminum alloy; and the welding speed is 2550mm/min. compared mechanical properties of the samples under different conditions, we got a conclusion that the strength and plastic of the aluminum alloy rim meet the technical requirements of the performance. The strength of the weld and heat affected zone when the vacuum rapid cooling, which is equivalent to quenching treatment, is higher than parent materials; and the spent solution and heat treatment plays a role of precipitation strengthening.Simulated the process of rim forming by the finite element numerical simulation, and analyzed the effect of different speeds and friction conditions on metal flow rate, equivalent strain, equivalent stress and the load - stroke curves, the conclusion is that the forming is best when the temperature is around 450℃, the friction factor is 0.1 and the extrusion speed is 10mm / s. And then determined the process parameters and forming equipment and designed the mold.The complete of the rim forming trial shows that the original process and die design is feasible. The rim could meet the technical requirements, reduced the cost and effective weight loss achieved. The program solved the key issues of aluminum alloy rim forming and achieved the desired objectives.