Forging process and Die Design for Aluminium Alloy Brake Shell
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The die-forging process and hot forging die design for LY11 Al-alloy brake shell was introduced,and the forging process characteristic of LY11 was investigated;the forging force of the material was analyzed,its heat treatment after forging was described.These are helpful to the forging process and heat treatment of the similar materials.Cite
Abstract The paper presents the results of a theoretical analysis of a new process of hammer forging of a connecting rod and the technology currently used. In the industry at present connecting rods are forged from extruded rods. The new forging technology assumes the use of a workpiece in the form of a cast preform. For the calculations, it has been assumed that the billet material will be a Ø30 × 148 mm rod and a cast preform. Two variants of preforms have been modeled, from which products of the assumed geometry with different degree of strain are obtained. Calculations were made using the finite element method (FEM) in the Deform 3D program. The input material was 2017A aluminum alloy in the form of rods and sand cast preforms. On the basis of the conducted research, it was found that the use of cast preforms reduces material waste by about 80% in relation to the technology of forging from the bar and reduces the energy consumption of the process by about 75%. Both geometrical variants of the forging preforms ensure obtaining a forging with the assumed shape and dimensions, although forging from the forging preform with a smaller degree of strain seems to be a safer variant in terms of the possibility of cracking of the material. This is supported by the lower strain and normalized Cockcroft–Latham integral values.
Hammer
Rod
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The traditional technique of forging aluminum wheels is mostly open-die forging. The mould structure of closed-die forging was designed,and the study on the forming technique of closed-die forging for aluminum alloy wheel was conducted. The analysis on the common defects during forming such as unfilled filling form,folding wheel windows and demoulding deformation was made and then solutions were put forward effectively. Research results show that positioning rotary forging blank with the shape,the radius R of mold in the key location and the structure of demoulding and unloading have a direct influence on the forming process. The closed-die forging process of aluminum wheels is feasible,and it is applied to the mass production of aluminum wheels.
Blank
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The filling capability of forging die is the key to design forging die and it exerts an important influence to the quality and life of die. In response to the difficulty in filling of forging die,and taking 2A12 aluminum alloy as the research object,the bar filling height after forging as the control objective,the finite element numerical simulation method was used to simulate the forging process. This test simulated the process of die forging,analysed the deforming behavior of the stuff and discussed the variety and distribution of temperature and strain。
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The development process of forming technology with forging is described. This technology has been developed from the original manual forging to radial forging in full automatic control. It has been pointed out radial forging technology has a series of advantages including high forging productivity , slight temperature reduction in the process of forging deformation and adequate surface deformation of the ingot or billet. The gross section fine grain material can be obtained by radial forging. One heat forging from ingot to finished products of high alloy with hard deformation can be realized.
Ingot
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Effects on the hot forging mould cracking of typical shell were studied through analyzing the process of the typical shell,switching between product drawing and forging drawing and the description of design principles and manufacturing process.In order to avoid closed-die forging and deformstion dead areas of the shell,the problem of center location between the blank center and the die center should be solved and the effect of the flash design on the forming force should be cared during the forging design.It provides a significant reference for hot forging mould process design,forging design and die structure design of titanium alloys shell.
Blank
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Forging die can be manufactured by methods of liquid die forging, and the wheel forging die(Φ 200mm) has been made by this process. In this paper, the process experiment is summarized, and the product isanalyzed.
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According to the forging blank requirements of a magnesium alloy shell,the parameters such as forging temperature,furnace holding time,clamping board temperature of the forging machine,forging time and so on of MB2 magnesium alloy forged on the general forging machine are determined by experiments.They provide some experiences for forging technology planning of this alloy.
Blank
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Aluminum alloy with high assay silicon SC100-T6has lower rate of thermal expansion and good abrasive resistance.But it is hard to be forged for its poor plastic property in room temperˉature and higher friction coefficient between the work piece and die at high forging temperature.The structural dimension of piston tail forging part and the key technology of die forging were analyzed in detail,then a three-step die forging process was determined which included blocker forging,finish forging and trimming.The structure of the forging die was designed and the feasibility of the proˉcess was verified by technological experiment.
Piston (optics)
Trimming
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Isothermal process
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The process of liquid forging test with H11 steel forging die was presented.The deficiency of former die structure was analyzed and then improvement solutions were proposed which includes the setting of anti-splashing device,cooling system and overflow device.
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