Transactions of Materials and Heat Treatment

Title：Prediction of forging defects and mold optimization for aluminum alloy wheels based on AFDEX

Authors： Wang Danchen Zhang Chengji Bian Yi Hu Mingwei Sun Weiling Gao Bingkun

Unit： Beijing Research Institute of Mechanical & Electrical Technology China Machinery Hua An Zhengxing Wheel Co. Ltd.

KeyWords： aluminum alloy wheel forging defects microstructure folding AFDEX

ClassificationCode：TG316.3

year,vol(issue):pagenumber：2018,43(4):33-36

Abstract：

Forged aluminum alloy wheels are generally of large size, complex shape and high processing accuracy, so the parameters of mold have a great influence on the quality of forgings. In the early stage of mold development for forging aluminum alloy wheels of a commercial vehicle, the possible defects of aluminum alloy wheels in the actual production was predicted by numerical simulation software AFDEX. Then, the predicted defects are confirmed by macrostructure observation and microstructure analysis of forged products, and the phenomenon of metal backflow is effectively avoided by optimizing the die fillet radius from R6 mm to R40 mm. Thus, the problem of folding is solved, and the actual results are consistent with the simulation prediction results. After the simulation, the tonnage is 7197 t, while the actual tonnage is 6600 t, and the error between them is about 7% which is within a reasonable and controllable range. Thus, the finite element numerical simulation AFDEX is adopted to predict the product performance which can control the research costs and shorten the product development cycle. At the same time, it also provides references for other product development.

Funds：

智能制造新模式应用项目(工信部联装〔2016〕213号)

王丹晨（1992-），女，硕士研究生；E-mail：15600929161@163.com；通讯作者：边翊(1976-)，男，硕士，研究员；E-mail：bianyi@jds.ac.cn

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