| The hub is a very important part of the car,and its performance directly affects the safety,comfort and appearance of the vehicle.Along with the intensifies of the automobile lightweight process,the importance of lightweight wheels gradually emerged.In this paper,the forming process of commercial aluminum alloy hub was studied to ensure the adoption of forging and spinning integrated process of commercial aluminum alloy hub.In this paper,the Gleeble hot compression test of 6061 aluminum alloy was carried out firstly.The real stress-strain curves at different temperatures and strain rates were obtained from the test.The constitutive equation of the 6061 aluminum alloy was fitted,and the variation law of stress with deformation temperature and strain rate was analyzed.The geometric characteristics of commercial aluminum alloy hub were analyzed and the forming process of commercial aluminum alloy hub was made.Forging finite element model of commercial aluminum alloy hub was built using Deform-3D finite element software according to the actual production.The numerical simulation of the forming process was made to observe the material flow,distribution of stress field and temperature field during the forging process;and the feasibility of the forging process was theoretically verified.In addition,the influence factors of grain size and distribution of large size aluminum alloy hub during the forging process were explored by numerical simulation.The influence laws of every factors on grain size and distribution of large size aluminum alloy hub were also summarized.Taking the forming force as the objective function,the main technological parameters affecting the forming force in large size aluminum alloy hub were studied in orthogonal experiment by numerical simulation.The order of factors affecting the forming force was obtained and the optimal combination of process parameters was determined.Finally,the spinning process of rim of commercial aluminum alloy hub was analyzed using simulation software Simufact.According to the observation of material flow in the rim during spinning process,the advantages and disadvantages of two spinning plans which are spinning the rim on the top and bottom separately and spinning the rim on the top and bottom at the same time were summarized and contrasted.In the end,the latter was used to form the commercial aluminum alloy hub.And the distribution laws of stress strain field and temperature field in spinning process were summarized at thesame time.The feasibility of the forming plan is proved theoretically which provides theoretical support and process reference for the forming of commercial aluminum alloy hub. |
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