Application of computer simulation for aluminium alloy forging technology advancement

Abstract

There was made an investigation of real manufacturing process of forging of brackets, made of AK6 aluminium alloy (technology-analogue). The purpose of investigations was the search of the possibility of increasing of economic efficiency of obtaining of die bracket forging due to the use of computer simulation in the software package QFORM. At the same time, there was set a task of correction of manufacturing process without replacement of the used deforming equipment, significant change of the existing pressing tool and without the change of the shape and sizes of die forging. For the virtual experiment purpose, the Unigraphics NX program was applied to create the three-dimensional models of die forging of bracket and open press tool, using drafts; which files were loaded into the front-end processor of the QFORM program. After that, the rheological properties of alloy were introduced together with temperature, rapid and power deformation modes, and friction factor. At the end of these operations, the processor was switched on. As a result, computer model of manufacturing process of stamping was obtained, and the model of plastic deformation of the billet during the stamping according to the technology-analogue was shown. Computer model analysis made possible the correction of manufacturing process, which accounting carried out the modeling of advanced technology. At the same time, the program made possible the creation of the dependence of stamping effort on the working stroke of the press, and illustration of all stages of deformation process from the billet to the final shape of die forging. As a result, computer simulation made possible to substantiate the changes in real technological process. According to the new technology, the experimental-industrial testing of stamping has shown that the properties and sizes of obtained die forgings met the requirements of the legal documents. Decreasing of the cost prise of forgings by near 30% led to the metal consumption decrease by 5%.