The Research And Development Of Casting-Forging Combined Process Forming Process Of Magnesium Alloy Control Arm Of Automobile

Though magnesium alloy casting process has excellent formability and low cost, itonly can be utilized in conventional low performance structures because of structuredefects and low mechanical properties. Forging magnesium alloy can perfectly meet theforming and performance needs of high performance structural components. However,the traditional process route is usually complex, leading to poor material utilization,long technological process, high cost of the products and small-scale application.In the study, the control arm of automobile was studied, with the foundation ofmagnesium alloy composite forming method, combining the low cost advantage of castform and the high quality, high performance of forging forming, the research anddevelopment of high performance Mg alloy control arm of automobile were proceeded.The billets were obtained by one squeeze casting forming, then the product of controlarm were formed by one isothermal forgingFirst, on the basis of the sample pieces of aluminum alloy control arm ofautomobile, the control arm model, which satisfied the service performancerequirements, was designed. Then, the control arm billet whose model can be obtainedby one forging forming was worked out. After that, the plastic finite element analysissoftware was adopted to simulate the (isothermal forging process. According to thesimulation results, the analysis to the deformation behavior, stress, strain andtemperature transformation of the forging process was executed, receiving thetechnological parameters which are supposed to be appropriate for the control armmanufactured by isothermal forging.Moreover, the Squeezing Casting process analysis was carried out to the designedMg alloy control arm of automobile. To be precise, the mold filling and solidificationprocess of Squeezing Casting process were simulated with casting simulation softwareMagmaSoft. According to the simulation results, the rationality of gating system andprocess parameters were analyzed, and the possible defects were predicted. Furthermore,the extrusion casting parameters and gating system were optimized to get suitableparameters.On the basis of mould manufacturing, combined with equipments and SqueezingCasting technological parameters concluded with simulation software, Mg alloy controlarm of automobile was trial-produced. The microstructure and properties of the final produced control arm were tested, so the two process can be optimized and the benchtesting was proceeded.