Advertisement

Isothermal precision forging of aluminum alloy ring seats with different preforms using FEM and experimental investigation

  • Yanqiu Zhang
  • Shuyong JiangEmail author
  • Yanan Zhao
  • Debin Shan
ORIGINAL ARTICLE

Abstract

7A09 aluminum alloy ring seat of airplane is subjected to isothermal precision forging. The influence of the different preforms on flow line, microstructures, mechanical properties, and defects of the forging is comprehensively investigated by means of experiments and FEM. Isothermal precision forging of the ring seat is implemented on the basis of three disk preforms with the height of 15, 25, and 35 mm, respectively. The experimental results indicate that the flow of metal along the radial direction increases with the increase in the height of the preform, and large plastic deformation of metal along the radial direction contributes to forming flow line of the forging. In the case of the preform with the height of 35 mm, the forging exhibits perfect profile, where there exist no defects such as underfilling and folding, while breaking of flow line frequently occurs. Furthermore, the high preform causes the forging to possess finer grain and substructure and consequently contributes to enhancing comprehensive mechanical properties. As a consequence, the preforging preform is appropriately designed so that high-quality forging with perfect flow line can be obtained by means of the optimum process procedure.

Keywords

Finite element method Aluminum alloy Bulk deformation Flow line Isothermal forging 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Sun ZC, Liu L, Yang H (2011) Microstructure evolution of different loading zones during TA15 alloy multi-cycle isothermal local forging. Mater Sci Eng A 528:5112–5121CrossRefGoogle Scholar
  2. 2.
    Zhang DW, Yang H (2013) Preform design for large-scale bulkhead of TA15 titanium alloy based on local loading features. Int J Adv Manuf Technol 67:2551–2562CrossRefGoogle Scholar
  3. 3.
    Luo J, Li MQ, Ma DW (2012) Microstructure and mechanical properties of 7A09 aluminium alloy after isothermal compression and solution treatment. J Mater Process Technol 212:1039–1048CrossRefGoogle Scholar
  4. 4.
    Rao KP, Prasad YVRK, Suresh K (2012) Anisotropy of flow during isothermal forging of rolled AZ31B magnesium alloy rolled plate in three orthogonal directions: correlation with processing maps. Mater Sci Eng A 558:30–38CrossRefGoogle Scholar
  5. 5.
    Jackson M, Jones NG, Dye D, Dashwood RJ (2009) Effect of initial microstructure on plastic flow behaviour during isothermal forging of Ti-10V-2Fe-3Al. Mater Sci Eng A 501:248–254CrossRefGoogle Scholar
  6. 6.
    Si JY, Han PB, Zhang J (2010) Design for Isothermal Forging of Ti-46.5A1-2.5V-l.0Cr-0.3Ni Alloy. J Iron Steel Res Int 17:67–73CrossRefGoogle Scholar
  7. 7.
    Cavaliere P, Cerri E, Evangelista E (2004) Isothermal forging of AA2618 + 20 % Al2O3 by means of hot torsion and hot compression tests. Mater Sci Eng A 387–389:857–861CrossRefGoogle Scholar
  8. 8.
    Deng KK, Wang XJ, GanWM WYW, Niea KB, WuK ZMY, Brokmeier HG (2011) Isothermal forging of AZ91 reinforced with 10 vol.% silicon carbon particles. Mater Sci Eng A 528:1707–1712CrossRefGoogle Scholar
  9. 9.
    Khalilpourazary S, Dadvand A, Azdast T, Sadeghi MH (2011) Design and manufacturing of a straight bevel gear in hot precision forging process using finite volume method and CAD/CAE technology. Int J Adv Manuf Technol 56:87–95CrossRefGoogle Scholar
  10. 10.
    Gangopadhyay T, Ohdar RK, Pratihar DK, Basak I (2011) Three-dimensional finite element analysis of multi-stage hot forming of railway wheels. Int J Adv Manuf Technol 53:301–312CrossRefGoogle Scholar
  11. 11.
    Shan DB, Xu Y, Lu Y (2000) Three-dimensional rigid-plastic finite-element analysis of the isothermal precision forging of a cylindrical housing. J Mater Process Technol 102:188–192CrossRefGoogle Scholar
  12. 12.
    Zhan M, Liu YL, Yang H (2001) A 3D rigid-viscoplastic FEM simulation of compressor blade isothermal forging. J Mater Process Technol 117:56–61CrossRefGoogle Scholar
  13. 13.
    Shan DB, Liu F, Xu WC, Lu Y (2005) Experimental study on process of precision forging of an aluminium-alloy rotor. J Mater Process Technol 170:412–415CrossRefGoogle Scholar
  14. 14.
    Puertas I, Luis Pérez CJ, Salcedo D, León J, Fuertes JP, Luri R (2013) Design and mechanical property analysis of AA1050 turbine blades manufactured by equal channel angular extrusion and isothermal forging. Mater Des 52:774–784CrossRefGoogle Scholar
  15. 15.
    Guo B, Sun CS, Zhang SC, Ge CC (2013) Isothermal forging process design for spray-formed FGH95 superalloy turbine disk based on numerical simulation. Rare Met 32:347–353CrossRefGoogle Scholar
  16. 16.
    Huang SH, Zong YY, Shan DB (2013) Application of thermohydrogen processing to Ti6Al4V alloy blade isothermal forging. Mater Sci Eng A 561:17–25CrossRefGoogle Scholar
  17. 17.
    Yang H, Zhan M, Liu YL (2002) A 3D rigid–viscoplastic FEM simulation of the isothermal precision forging of a blade with a damper platform. J Mater Process Technol 122:45–50CrossRefGoogle Scholar
  18. 18.
    Petrov P, Perfilov V, Stebunov S (2006) Prevention of lap formation in near net shape isothermal forging technology of part of irregular shape made of aluminium alloy A92618. J Mater Process Technol 177:218–223CrossRefGoogle Scholar
  19. 19.
    Rao KP, Prasad YVRK, Suresh K (2011) Materials modeling and simulation of isothermal forging of rolled AZ31B magnesium alloy: anisotropy of flow. Mater Des 32:2545–2553CrossRefGoogle Scholar
  20. 20.
    Zhang DW, Yang H, Li HW, Fan XG (2012) Friction factor evaluation by FEM and experiment for TA15 titanium alloy in isothermal forming process. Int J Adv Manuf Technol 60:527–536CrossRefGoogle Scholar
  21. 21.
    Shan DB, Xu WC, Han XZ, Huang XL (2012) Study on isothermal precision forging process of rare earth intensifying magnesium alloy. Mater Sci Eng B 177:1698–1702CrossRefGoogle Scholar
  22. 22.
    Luri R, Luis CJ, Salcedo D, LeónJ FJP, Puertas I (2013) FEM analysis of the isothermal forging of a connecting rod from material previously deformed by ECAE. Procedia Engineering 63:540–546CrossRefGoogle Scholar
  23. 23.
    Zhang YQ, Xu FC, Jiang SY, Shan DB (2011) Influence of fire times on the microstructure and mechanical properties of forgings with complex shape. Adv Sci Let 4:1027–1031CrossRefGoogle Scholar
  24. 24.
    Zhang YQ, Jiang SY, Zhao YN, Shan DB (2013) Isothermal precision forging of complex-shape rotating disk of aluminum alloy based on processing map and digitized technology. Mater Sci Eng A 580:294–304CrossRefGoogle Scholar
  25. 25.
    Zhang YQ, Shan DB, Xu FC (2009) Flow lines control of disk structure with complex shape in isothermal precision forging. J Mater Process Technol 209:745–753CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2014

Authors and Affiliations

  • Yanqiu Zhang
    • 1
  • Shuyong Jiang
    • 1
    Email author
  • Yanan Zhao
    • 1
  • Debin Shan
    • 2
  1. 1.Industrial Training CentreHarbin Engineering UniversityHarbinChina
  2. 2.School of Materials Science and Engineering, Harbin Institute of TechnologyHarbinChina

Personalised recommendations