| Abstract:With the fast development of modern society, the demand for some complex shape components with enhanced properties gets more and more. And the single casting or forging process is insufficient for this kind of components. In this study, the casting-forging integrated forming technology was adopted to prepare6061aluminum alloy automobile brake caliper. Numerical simulation and experimental study on the6061aluminum alloy automobile brake caliper were also adopted to study this forming process. The main research work and results are as follows:(1) The software FLOW-3D was used to simulate the filling process of6061aluminum alloy automobile brake caliper prepared by casting-forging integrated forming technology. Effect of mold structure, the melt pouring temperature, injection speed and mold temperature on the filling process and defect formation process of the6061aluminum alloy automobile brake caliper were systematically studied. The mold structure and filling process parameters were optimized and the related experimental verification was done. The experimental parameters were consistent with the simulation results, and the optimal combination of parameters:pouring temperature is760℃, injection speed is66mm/s and the mold temperature is about250℃. Under these parameters, a6061aluminum alloy automobile brake caliper with complete filling and nonporous can be obtained.(2) Casting-forging integrated forming technology was adopted to prepare6061aluminum alloy automobile brake caliper. Effect of forging force and forging start-up time on the solidification feeding, microstructure and mechanical properties of the6061aluminum alloy automobile brake caliper were systematically studied. The forging process parameters were optimized. The results show that the shrinkage cracks within6061aluminum alloy automobile brake caliper can be eliminated by the forging deformation, the microstructure is compacted and the dendrite is broken to fine grains. The optimal forging process parameters from the experiment are as follows:forging force270-360MPa, forging start-up time is2-4s.(3) The6061aluminum alloy automobile brake calipers with high mechanical properties are obtained by casting-forging integrated forming technology. The ultimate tensile strength, elongation, hardness of6061aluminum alloy automobile brake caliper with T6heat treatment were354MPa,11.8%and138.53HV, which were improved by89.3%,237.1%and45.2%, respectively, compared with that of caliper without forging.44figures,15tables,92references. |
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