Study On The "Rotary-Spinning" Preparation Technology Of 6061 High Strength Aluminum Alloy Wheel

As a typical local loading technology,rotary forging and stagger spinning is an effective technique to realize high performance lightweight components.Through Local contact between die and blank and Cumulative local plastic deformation can realize the forming,which has many disadvantages like labor-saving and effective control of uneven deformation.Compared with the traditional welding,casting,forging and other methods,It can effectively reduce the equipment tonnage,energy saving and emission reduction,reduce the cost of production and improve the forming quality of the hub by the process of “rotary-spinning”.“rotary-spinning” wheel hub has the advantages of high quality and low price,which can expand the high-end car market of original forging hub of and extended to the low-end car.There is a wide range of applications and development space in the future.According to the classic five spoked wheels,3D simulation model was built.On the basis of actual investigation and empirical value,the technological route of rotary forging to prepare preforming billet and two-pass stagger spinning to obtain wheel rim was established.Also,feasible technical parameters and simulation models ware built.This paper made a detailed analysis on the forming process of rotary wheel preform with Deform-3D finite element simulation software.The main process parameters were analyzed by forming quality and effect of mold filling,including the relative height(H/D),autorotation of rotary head,forming process,inclination of rotary head,the initial temperature of billet,revolution of rotary head,feed speed.The mechanism is expounded through the metal flow velocity,stress and strain distribution,rotary line,edge uplift.Finally,the optimal parameters were obtained.At the optimum parameters,Forming tonnage of rotary forging was only 1/5 tonnage of ordinary forging,which can greatly reduce the equipment tonnage and reduce processing cost.The strain is concentrated in the junction of the spokes and rim,which can Improve the strength and avoid the weakness of the traditional process to reduce the possibility of cracking.With better results as reference,mold base of rotary forging was designed.Also,the part of the rotary forging machine frame was designed,which would lay the foundation for future related experiments.The simulation of two-pass stagger spinning was carried out by using SIMUFACT finite element software.The first-pass stagger spinning used small round roller.Under the action of splitting,it would produce a large uplift.At the same time,the stress and strain are not only distributed in the active region of spinning wheel,but also in the non-deformed zone,which may cause the surface with spinning mark or other surface quality problems.These forming problems need to be corrected by the second-pass stagger spinning.In the second-pass stagger spinning,a large round wheel is adopted,which was favorable for the metal flow with small uplift.The stress and strain were all in line distribution,which can effectively improve the surface quality of the rim.The original wheel rim structure can be obtained by two pass stagger spinning,and the feasibility of the design scheme was verified.