The Research On The Forming Process Of Aluminum Alloy Components With Complex Cross Section

The geometry of the aluminum alloy component with complex cross section is extremelycomplex. The center of this kind of components is circular boss and the round is high ribs,which leads the overall forming is very difficult. This components need to bear a large impactload, so the requirements of mechanical properties about this components is very high. Whenthis kind of components is manufactured by direct forming of cylinder rough, there are oftensome serious quality problems existing in the components. For example, the edge area is notfilled completely and the defects of folding or uneven local deformation appear. In addition,the eventual forming load is usually very high. To achieve this kind of complex componentwith high mechanical properties by overall forming, and at the same time avoid the defectabove, the preforming optimization design was conducted in this paper.Based on the method of combining finite element simulation and experiment, The metalmaterial regular pattern during the overall forming of the aluminum alloy component withcomplex cross section was researched in this paper. The material stress, strain, flow speed andthe load and other physical field quantities during the forming process were also analyzed. Inaddition, the formation mechanisms about the defects of edge area unfilled completely, folding,uneven local deformation and high load were analyzed.For the problems above, according to shunt forming principle, the preform optimizationprogram of the aluminum alloy component was proposed. To realize the metal material shuntforming, reduce the resistance of the material filling the cavity and the forming load, inaddition, to improve the uniformity of material deformation and avoid the defects of foldingand unfilled completely during the forming process, the hollow preformed blank was adoptedin the program. To obtain the optimal key structural parameters of the performed blanks, the keystructural parameters including the hollow concave direction, the influence of ΔH/H andR/R0to stress, strain and the load during the final forming should be researched firstly.Compared with the original program, the optimal structural parameters obtained made theforming load reduce by30%, the deformation was more uniform and the defects of foldingand unfilled completely were avoided.The experimental trial was conducted through using the optimized forming program andthe qualified workpieces were successfully produced.Thetoughness, microstructure andmechanical properties of the samples obtained from the different parts of workpieces wereresearched. The results showed that the indicators of the workpieces obtained by optimizedforming program were improved greatly, compared with the original program, which verifiedthe rationality of the optimized forming program.