Analysis of Material Characteristics and Forging Parameters for Flashless Forged Aluminum-Matrix Composites
Analysis of Material Characteristics and Forging Parameters for Flashless Forged Aluminum-Matrix Composites
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DOI：
10.1080/10426914.2013.822986
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发表时间：
2014-02
影响因子：
4.8
通讯作者：
M. Stonis;Tilmann Rüther;B. Behrens
中科院分区：
文献类型：
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作者：
M. Stonis;Tilmann Rüther;B. Behrens
最近的研究涉及在实验室条件下生产的铝基复合材料的基本可锻性。这些研究项目集中在冶金方面，并通过推导流动曲线来研究成形性。与实验室条件相反，工业用途需要大量原材料，并在真实条件下进行。这些情况尚未得到分析。本文介绍了铝基复合材料的力学优点与无闪蒸锻造工艺的结合。与相同重量的传统锻造部件相比，其优点可以概括为更高的部件强度。新导出的流动曲线证明了成形性，并用于评估基本锻造参数。在传统锻造工艺中使用高锻造率的第一次锻造试验导致零件断裂，因此需要降低变形率。由于使用了金属基复合材料（MMCs），基段塞材料的变形率更高，但必须降低。使用传统的锻造压力机（如螺旋压力机）会导致材料失效，如裂纹，因为锻造al - mmc需要降低20mm /s的成形速度。为了降低成型速度，建议使用液压机。对新开发的无闪锻工艺进行了有限元分析，描述了锻模内材料的基本成形操作（展开、拉长和爬升）。提出了一种基于Al-MMC的无闪锻工艺布置新策略。
Recent research dealt with the basic forgeability of aluminum-matrix composites produced under laboratory conditions. These research projects concentrated on metallurgy and, by deriving flow curves, on formability. In contrast to laboratory conditions, the industrial use requires large batches of raw materials and takes place under real conditions. Those conditions have not yet been analyzed. This paper describes the combination of mechanical advantages of aluminum-matrix composites and a flashless forging process. The advantages can be outlined as higher part strength, compared to conventional forging parts with the same weight. Newly derived flow curves demonstrate formability and were used to evaluate basic forging parameters. The first forging trials in a conventional forging process using a high forging rate resulted in broken parts and therefore required a reduced deformation rate. The matrix slug material provides a higher deformation rate but has to be reduced, due to the use of metal-matrix composites (MMCs). Using a conventional forging press (e.g., screw press) causes material failures likes cracks, because forging Al-MMCs requires a reduced forming speed of 20 mm/s. Reducing the forming speed, hydraulic presses are recommended. Finite Element (FE) analysis of the newly developed flashless forging process is described and depicts the basic forming operations (spreading, elongating and climbing) of the material in the forging die. Altogether a new strategy for a flashless forging process layout with Al-MMC is shown.