Study On Forming Of Thin-walled Shell Magnesium Alloy Part With Ring Rib

With the rapid development of aerospace high-tech industries, the large light-alloy andthin-walled parts which have lightweight structure, small complex coefficient of the shape areurgent need to reduce weight and improve overall performance. The ring rib-containing andthin-walled magnesium alloy is one of the typical examples. Currently, the method of formingsuch parts are still dominated by mechanical processing and casting, the former will destroythe metal flow lines, making the parts can not meet the performance requirements. The latterwill induce parts casting defects, and ultimately can not be used in high performancerequirements occasions. Therefore, the development of a new forming process is necessary.In this paper, the ring rib-containing and thin-walled magnesium alloy has been studiedand a new forming process was developed. The details are as follows.According to the characteristics of the part, the forming process was developed andextrusion part is determined. The forming process is：Cutting-Upsetting-Punching-Radialsqueeze-Aging treatment-Machining. The stress-strain curve of metal in deformation zonewas obtained by means of numerical simulation software DEFORM. We could get the law ofthe metal flow by the stress-strain curves, and then partition the deformation zone. It couldprovide a basis for design of the split punch.The effects of the appearance of the split punch structure, key structural parameters (theradius of curvature R1, R2) on the filling of the rib during the forming process were studiedby means of numerical simulation software DEFORM. The best structural of the split punchwas determined and got ready for the optimization of parameters of the extrusion.On the basis of optimization the structure of the split punch, we analyzed the effect of theextrusion temperature, extrusion speed and friction coefficient on the forming process, such as load, damage, equivalent stress and equivalent strain. Get the best parameters of the radialsqueeze.The extrusion die was designed according to the simulation results, which providestheoretical basis for the production and application of such parts.