Study On The Plastic Forming Process Of Complex Forgings 5A06 Aluminum Alloy

The lightweight aerospace equipment has a wide demand for the complex components of high performance aluminum alloy,integral plastic forming is the main forming method to make the mechanical properties of such parts meet the requirements of products.In this paper,the whole plastic forming process of 5A06 aluminum alloy complex components with "tian" shape structure and "ear" on both sides is studied by theoretical analysis,numerical simulation and experiment.Four forming schemes of 5A06 aluminum alloy complex components are simulated by using Deform software,during the forming process of each scheme,the metal flow rule and the possible defects such as folding and not be fully filled are analyzed.The five "large deformation work zones" of complex components in the metal flow shunt are most likely to produce extrusion defects,Only the projection of the billet in the bottom of the concave mold assembly contains the four protrusions of the "tian" four-lobe concave mold and the metal flow can be reasonably distributed to avoid the defect of extrusion.The forming process scheme of the component upsetting preforming and composite extrusion final forming are determined.The axial shunt model of metal flow during composite extrusion is established,which provides a basis for theoretical calculation of forming force.The partial open forming method is adopted to reduce the forming force of composite extrusion effectively.The preforming and final forming molds are designed.Both sets of molds are composed of three parts: convex module,ejector linkage device and concave module.The method of replacing the punch of the convex die in the convex module and the "field" shape jacking block in the ejector linkage device is adopted.The utility of other parts of two sets of molds is realized,the cost of the trial mould is reduced and the manufacturing cycle is shortened.According to the numerical simulation results,the forming experiment of 5A06 aluminum alloy complex components is carried out using the designed tooling and themicrostructure and properties of the forging were tested,the experimental results are in good agreement with the numerical simulation and theoretical analysis.The tensile strength of the forging is 5% higher than that of the raw materials,and the elongation is 40% higher,grain size is obviously refined.The shape,size and mechanical properties of the forging meet the requirements of the products,it provides a reference for the formulation of the plastic forming process of complex components for lightweight aerospace equipment.