Analysis On The Forging Defects Of Audi Aluminum Alloy Wheel

The aluminum alloy wheel will replace the steel wheel gradually because of it's many excellences. Forging aluminum wheel is a more cost-effective method compared to other bulk forming method, so that forging aluminum alloy becomes a potential industry. The defects that appear in the forging process are the disadvantageous factors for the development of forging aluminum alloy industry, and they are the problems that really need to be solved. The analysis of forging defects of aluminum alloy wheel is based on simulation and experimentation which is from manufacture and based on finite element software, the causes of the defects can be found through the simulation and experimentation.First, on the basis of FEM simulation study this paper systematically sums up key techniques of numerical simulation, theory model and rules relevant to defect simulation. Second, the defects that appear in the forging process are classified, the factors that inducing the defects from human, machine, environment and material are systematically summarized. Then, the defects of aluminum alloy are analyzed. At last, the incomplete filling during per-forging and the lap during finish-forging are simulated by DEFORM aiming at defects that appear in the manufacture of Audi aluminum alloy wheel. Other typical defects of Audi aluminum alloy wheel are analysed and summarized. Base on the different simulating conditions the potential causes of each defect are summarized, and the defect-factor matrix are built that are corresponding to defects.The defect-factor matrix is compact and direct, it can diagnose the typical defects that appear in the produce process, the variable can be modified to instruct the manufacture process.