Numerical Simulation And Optimization Of Large Al Alloy Part Forging Process

As our country's aviation industry's development on the direction of modernization and high-speed, the requirement of lightweight aircraft becomes larger and larger. The trend that Al alloy take place of Fe alloy becomes larger day by day, especially changing the Fe alloy structural component on the aircraft into Al alloy forging or casting part. As the beginning of the Large Plane Program in our country, the forging processing of Al alloy become the focus of public. Now, there are three difficulties in the Al alloy forging processing, they are the strict requirement of quality, the complex forming processing and high product cost.This paper briefly introduced the technology of heavy Al alloy die forging and the development status of home and abroad, choosing a special Al alloy part as the typical forge piece, particularly introduced the work in CAD and CAE of die forging.The feasibility, stability, quality of forming (including brimming forming, replicate and organize disfigurement), material utilize efficiency and how to reduce load, how to improve mould life-span are all emphasized when we working out forming process of Al alloy heavy part because of its complicated forging process. By the use of the CAD system in CATIA, the forming process and dies of Al alloy heavy part have been set up. In this paper, through adopting rigid-visco plastic finite element method (FEM) and using American advanced software Deform. Through FEM simulation, Later, through a series of simulations analyzed the relations between maximal forming load and friction coefficient, press velocity, the warm-up temperature of die. And the relations between tool wear and friction coefficient, press velocity, hardness of the die were also analyzed. At the end, validated the rationality of the process and die of the Al alloy forging through examination, contrasted the results between simulation and examination, summarized the succeed experience.The technology of forging, FEM simulation and mould CAD are integrated through this research. It helps to shorten developing period, improve life of die, and cut down the cost, etc. The progeny of the research can provide accordance for other crankshaft'producing and be used to guide producing directly.