Study On Forming Uniformity Controland Die Structure Optimizationof Large Aluminum Alloy Shell Forging

With the development of the aerospace industry, lightweight component hasbecome an urgent need, and its development toward the direction of large-scale,integrated, complex shape.Large aluminum alloy forgings, due to its excellentcomprehensive properties, has been widely used in critical load-bearing componentsof aviation industry, and the working condition is very bad, therefore, this kind offorgings require high mechanical properties.This large aluminum alloy shellforgingstructure is very complex. Therefore forming process often exist some forgingissues such as forming uneven,the forming load is too large, the low utilization rate ofmaterials and hot forging die failure.The preform, process parameters and hot forging die structure of the researchtargetwere studiedusing finite element analysis technology,artificial intelligencetechnology and die failure theory.The main research contents and research results areas follows:①Optimization of the forging preformbased on finite element technology. Theforging process of large aluminum alloy shell forging of7050aluminum alloy issimulated using the finite element software DEFORM.Using different preform, theforming load, strain uniformity, grain uniformity anddistribution of flash wereanalyzedin the forming process.②Process parameters of multi objective optimization of the forging formingbased on RBF GA optimization algorithm.In order to optimize the forming processparameters of the forging, multi objective optimization and evaluation methods basedon RBF GA optimization algorithm was proposed. The temperature, strain rate,friction factor and flash land height that obviouslyaffect forming process wereoptimized.③Optimization and design of the hot forging die structure and analysis the coldforming process.Through the analysis of the die failure,temperaturefield and stressfieldofthe hot forging forming process wereanalyzedusing the finite element analysissoftware DEFORM, the relationship of different die structure and diefailurewerestudied.Finally, the die structure has been optimized and the final forgingdie and cold forming die have been designed.And the stress, strain, damage and loadof the cold forming process wereanalyzed. The thesisresearch work can provide reference for the optimization of formingprocess and die structure of the same type parts which has engineering value.