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Metals 2019, 9(2), 207; https://doi.org/10.3390/met9020207

Simulation and Experiment of Manufacturing Process for Structural Aluminum Parts with Hard to Plastic Forming

School of Mechanical Engineering, Kyungnam University, 7 Kyungnamdaehak-ro, Masanhappo-gu, Changwon-si 51767, Korea
Received: 17 January 2019 / Revised: 3 February 2019 / Accepted: 7 February 2019 / Published: 10 February 2019
(This article belongs to the Special Issue Computational Methods in Manufacturing Processes)
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Abstract

A process comprising a hot extrusion process and a warm forging process was designed to form an umbrella-shaped aluminum structural component with a high degree of difficulty for the plastic forming method. A circular cylindrical part was extruded with a hot extrusion process, and then an embossing part was produced with a warm forging process. The formability and the maximum load required for forming were then determined using a forming analysis program. The hot extrusion process was executed at 450 °C under the extrusion speed at 6 mm/s, while the warm forging process was executed at 260 °C under the forging speed at 150 mm/s. The simulation results showed that the load required for hot extrusion was 1019 ton, while the load required for the warm forging was 534 ton. The umbrella-shaped part was manufactured by using a 1600 ton capacity press. The graphite lubricant was coated on the mold as well as the material. A forming experiment was performed under the same condition with the simulation condition. The portion where extrusion was done became elliptical with the α-Al phase elongated towards extrusion direction. Whereas, the α-Al phase became circular in the forged portion. The tensile strength value was found as 345 MPa, while elongation rate was 12%. Meanwhile, Vickers hardness value at the extruded portion was 105 HV, and it was 110 HV at the forged portion. View Full-Text
Keywords: hot extrusion; warm forging; simulation; aluminum; manufacturing process hot extrusion; warm forging; simulation; aluminum; manufacturing process
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Jin, C.K. Simulation and Experiment of Manufacturing Process for Structural Aluminum Parts with Hard to Plastic Forming. Metals 2019, 9, 207.

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