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Abstract：
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In order to study the deformation characteristics of 4032 aluminum alloy piston during the hot die forging process deeply, a thermo-plastic coupled finite element model of hot die forging process for a typical piston was established, and the temperature field, the flow law of materials and the strain-stress state at the different deformation areas of blank during the forging process were studied in detail. Then, the expected mechanical performance and the mechanism of potential forging defects for the forged pistons were analyzed. Furthermore, the forging force curve and the overall dimension of the forged pistons were obtained, and the rationality of the finite element model was verified by comparing the simulation results with the key geometric parameters of the actual forged pistons. The simulation results show that the material deformation of piston is caused by piercing and backward extruding of upper die, the material deformation mainly occurs in the areas near the piercing and stepped surfaces of upper die, and the blank is in a three-way compressive stress state during the forging process. In addition, the forging defects such as micro-folding, scratching, material peeling on the inner surface of piston and the process problems such as insufficient filling and height unevenness of piston skirt are mainly caused by the friction of die and the sudden change of material flow directions. Thus, the surface precision and the lubrication effect of upper die should be strictly controlled, and the smooth design on the axial edges of die should be paid attention in the actual production process.
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Funds：
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国家重点研发计划“智能农机装备”重点专项（2017YFD0700200）;中国博士后科学基金（2018M643627）
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AuthorIntro：
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张超（1989-），男，博士研究生，E-mail：zhangc_xjtu@qq.com；通讯作者：赵升吨（1962-），男，博士，教授，E-mail：sdzhao@xjtu.edu.cn
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Reference：
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