Transactions of Materials and Heat Treatment

Title：Forming process design and DEFORM3D simulation optimization for a complex aluminum alloy forging

Authors： Wang Songwei1 2 Zhang Shihong1 Chen Yan1 Song Hongwu1

Unit： (1.Institute of Metal Research Chinese Academy of Sciences Shenyang 110016 China 2.School of Materials Science and Engineering University of Science and Technology of China Hefei 230026 China)

KeyWords： aluminum alloy lightweight mould DEFORM3D numerical simulation forging technology forging blank shape

ClassificationCode：TG316

year,vol(issue):pagenumber：2018,43(5):0-0

Abstract：

In order to meet the requirements of “lightweight” and “replace steel with aluminum” for a component of railway vehicle, the forming process of a aluminum alloy forging was researched, and the parameters were optimized by DEFORM3D finite element simulation. Then, the qualified products were obtained, and the weight was reduced by 65% comparing with original steel castings. The problems of uneven metal flow,incomplete forming and higher forging pressure during the forging process for parts with complex asymmetric structure were analyzed by numerical simulation, and the metal flow direction and cavity filling mode in deformation process were improved by reasonable design of mould and flash groove structure and optimizing the shape and size of blank. Finally,the forgings with good surface quality and mechanical properties were obtained by production tests which provided a reference for the production of this kind of forgings.

Funds：

沈阳市重点科技研发计划项目（17-32-6-00）

作者简介：王松伟（1990-），男，博士研究生 Email：swwang16b@imr.ac.cn 通讯作者：张士宏（1962-），男，博士，教授 Email：shzhang@imr.ac.cn

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