Precision forging technology for aluminum alloy

doi:10.1007/s11465-018-0477-y

Front. Mech. Eng.

2018, Vol. 13

Issue (1) : 25-36 https://doi.org/10.1007/s11465-018-0477-y

REVIEW ARTICLE

Precision forging technology for aluminum alloy

Lei DENG¹, Xinyun WANG¹(

), Junsong JIN^1,², Juchen XIA¹

¹. State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China
². Research Institute of Huazhong University of Science and Technology in Shenzhen, Shenzhen 518057, China

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Abstract

Aluminum alloy is a preferred metal material for lightweight part manufacturing in aerospace, automobile, and weapon industries due to its good physical properties, such as low density, high specific strength, and good corrosion resistance. However, during forging processes, underfilling, folding, broken streamline, crack, coarse grain, and other macro- or microdefects are easily generated because of the deformation characteristics of aluminum alloys, including narrow forgeable temperature region, fast heat dissipation to dies, strong adhesion, high strain rate sensitivity, and large flow resistance. Thus, it is seriously restricted for the forged part to obtain precision shape and enhanced property. In this paper, progresses in precision forging technologies of aluminum alloy parts were reviewed. Several advanced precision forging technologies have been developed, including closed die forging, isothermal die forging, local loading forging, metal flow forging with relief cavity, auxiliary force or vibration loading, casting-forging hybrid forming, and stamping-forging hybrid forming. High-precision aluminum alloy parts can be realized by controlling the forging processes and parameters or combining precision forging technologies with other forming technologies. The development of these technologies is beneficial to promote the application of aluminum alloys in manufacturing of lightweight parts.

Keywords precision forging aluminum alloy closed die forging flow control forging hybrid-forming technology

Corresponding Author(s): Xinyun WANG

Just Accepted Date: 29 September 2017 Online First Date: 13 December 2017 Issue Date: 23 January 2018

Cite this article:

Lei DENG,Xinyun WANG,Junsong JIN, et al. Precision forging technology for aluminum alloy[J]. Front. Mech. Eng., 2018, 13(1): 25-36.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-018-0477-y
https://academic.hep.com.cn/fme/EN/Y2018/V13/I1/25

Fig.1 7A04 aluminum alloy casing

Fig.2 YK34J-1600/1250 multidirectional closed die forging hydraulic press

Fig.3 Isothermal forged part: (a) Rotor [18] and (b) housing [21]. Reprinted from Ref. [18,21] with permission from the Jounal of Materials Processing Technology

Fig.4 Isothermal forging dies of rotating disk. (a) Upper die; (b) lower die. Reprinted from Ref. [22] with permission from the Materials Science and Engineering A

Fig.5 Sketch of local loading forging. Repoducted from Ref. [29] with permission from the Jounal of Materials Processing Technology

Fig.6 Hatch forged by local loading. Reprinted from Ref. [34] with permission from the Jounal of Materials Processing Technology

Fig.7 Schematic diagram of metal control forging by middle relief cavity. Reproduced from Ref. [36] with permission from the Journal of Plasticity Engineering

Fig.8 Schematic diagram of flow control forging of aluminum alloy wheel. Repoducted from Ref. [41] with permission from the Jounal of Materials Processing Technology

Fig.9 Schematic diagram of flow control forging with back pressure. (a) Scroll rotor; (b) axisymmetrical flanged component. Reproduced from Ref. [49] with permission from the Jounal of Materials Processing Technology

Fig.10 Vibration-enhanced forging die set with lubricant replenishment. Reproduced from Ref. [56] with permission from the Jounal of Materials Processing Technology

Fig.11 Distribution of lubricant in vibration-enhanced forging process. Reproduced from Ref. [58] with permission from the International Journal of Machine Tools and Manufacture

Fig.12 Schematic diagram of a single-step drawing and forging hybrid method. Reproduced from Ref. [50] with permission from the Journal of Materials Processing Technology

Fig.13 Principle of boss formation by compression and drawing hybrid method. Reprinted from Ref. [72] with permission from CIRP Annals-Manufacturing Technology

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