Study On Isothermal Forming Process Of 6063 Aluminum Alloy Integral Rim

With the constant progress of society,the automobile industry has witnessed a rapid development and environmental pollution caused by vehicles has also become increasingly serious.In this case,the car’s energy saving and environmental protection are more stringent.Car rim is an important part of the car,its weight and car fuel consumption is closely related to the reduction of 1% of the weight of the rim,car driving,fuel consumption will be reduced by 2%.Aluminum Alloy Rims As the most used light alloy rims currently used in small cars,the alloy rims mainly include forged aluminum alloy rims and cast aluminum alloy rims,and the cast aluminum alloy rims make up 90% of the aluminum alloy rims.However,the mechanical properties,quality and mechanical properties of forged aluminum alloy wheels are better than those of cast aluminum alloy wheels,which are promising for casting aluminum alloy wheels.In this paper,based on the rim overall forging process ideas,combined with the aluminum alloy material and the structure characteristics of the rim itself,the use of isothermal forging process method is proposed to form a one-time overall shape of the aluminum alloy wheel.The finite element numerical simulation software DEFORM was used to simulate the isothermal forging of the 6063 aluminum alloy wheel.Through simulation and post-processing analysis,the blank size,load size,temperature field,equivalent strain field,equivalent stress field and metal flow characteristics of the rim were obtained.The relevant data simulated by the forming process provide the basis for a reasonable mold structure design.In order to explore the effect of process parameters on the isothermal forming of the 6063 aluminum alloy wheel,nine orthogonal simulation experiments were designed.The effects of the three main process factors such as deformation speed(1mm/s,3mm/s,5mm/s),forging temperature(430 ℃,450 ℃,470 ℃)and friction coefficient(0.2,0.4,0.6)were analyzed.The best process parameters are obtained.Integral wheel isothermal forging dies were designed and isothermal forging tests were performed.The numerical simulation results show that the isothermal forging process is suitable for the overall forming of 6063 aluminum alloy wheels,and the formed forgings have no defects such as folding.The forging load tends to decrease as the deformation speed decreases,the forging temperature increases,and the friction coefficient decreases.Among these three process factors,the most important influenceon isothermal forging is the deformation speed,followed by the forging temperature,and finally the friction coefficient.Through the analysis of the numerical simulation results,the best process parameters are: the deformation speed is 1mm/s,the forging temperature is 450℃,and the friction coefficient is 0.4.Based on the results of numerical simulation,the isothermal forging die for 6063 aluminum alloy analog wheel rim was designed and tested.The results show that it is feasible to use the isothermal forging forming for the overall aluminum alloy wheel.The internal microstructure and surface quality of the forging are better than that of the ordinary forged and casted wheels.Isothermal forging experiments also verified the accuracy of the finite element numerical simulation results.