The Forming Process Research Of 7A04 Aluminum Alloy Pedestal With Large Ribs Complicated Cross Section

Parts involved in this topic have ribs both inside and outside, Cross‐section is complex, and it is not axisymmetric. The original process was welded together by a steel plate, weighing is large, and it may have some welding defects. In this research, 7A04 aluminum alloy be used instead of steel, and use technology of Isothermal precision plastic forming instead of welding. Forming parts on the basis of our existing equipment, Aims to Weight loss on the premises of part excellent performance. This topic will be a certain reference value in weight loss of many similar parts, as well as the forming of complex cross‐section parts.The research method is on DEFORM‐3D computer numerical simulation software combined with experimental. Proposing preliminarily scheme is simulated. There are some problems in the analysis of simulation results, for example: Founding that the stiffener of workpiece folding. And our equipment do not have enough forming load. A new forming process is formulated through the analysis of this series of problems, that is, Blanking�'Pier extrusion�'Forward extrusion�'local forming�'Reshaping. New process scheme have be simulated as well as optimized. Flowing velocity vector, equivalent strain and load force of simulation process have be analyzed. There are no obvious defects. Deformation of the workpiece is uniform. Load reduced to about 1200t from 2800t, and it accord with simulation results.Based on the simulation, we design the mold assembly drawing, and trial production. The results show that: The forming of cross‐section parts should not be used directly forming. Otherwise, some of the parts may have a lot of deficiencies that affect performance parts. We use the isothermal precision plastic forming technology to form parts gradually, not only able to reduce defects, but also reduce the forming load, and parts will have the better mechanical properties. Throughout the experimental results and simulation results are consistent. Inside surface of the workpiece have high precision. Forming parts fully meet the performance requirements. Weight of the workpiece after machine‐made is 10Kg. Comparing with previous forming weight loss 30%. Lightweight requirements have achieved.