Prevention of thin flash along the process chain for the precision forging of aluminum

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One way to save material and increase the accuracy of forged parts is the forming in closed dies. This process is continually spreading in forging industry. Due to the low flow resistance of aluminum materials and the resulting tendency to form thin flash this technology is not applied in the aluminum forging industry.The aim of this research project is the realization of flashless precision forging of aluminum long pieces. A design guide shall be established that enables the development of forging tools to facilitate the flashless forging of aluminum along the process chain. Conditions for the flashless forging include a close and constant parameter window (e.g. the temperature of tool- or workpiece) and tool designs for thin flash prevention. The occurence of thin flash can be avoided by adjusting the process window as well as by a suitable tool concept. Therefore, generally applicable models are developed to determine the occurence of thin flash by FEA-simulation. An optimal parameter window is elicited in the FEA-simulations. Existing tools and concepts for preforming and finish forming of long pieces are combined into a complete process chain. The prevention of thin flash shall be realized by a suitable material flow and by sealing if necessary. This new process chain is validated in a small series.