Formability Analysis and Die Design for Forging an Aluminum-Based Metal Matrix Piston
Date Issued
2010
Date
2010
Author(s)
Huang, Shih-Ting
Abstract
Due to its high specific strength and light weight, aluminum-based metal matrix composite (AL/MMC) attracts much attention from the industry for manufacturing the high strength structural components. Thus the forming method of relevant products is the key technology in the development of AL/MMC. Among the manufacturing processes for AL/MMC products, the forging process has much potential because of its competitive productivity and performance in the effective production of components with complex shapes. In the present study, the forging formability of an A6061/Al2O3 MMC piston was examined. The commercial code DEFORM-3D was employed to perform the forging simulations and the material properties of A6061/Al2O3 at elevated temperatures obtained from the compression tests were used as the input data for the finite element simulations. The influence of forging process parameters on the formation of A6061/Al2O3 piston was studied first. This study took material, characteristics modeling, and forging load of material during formation as indicators, investigating the influence of process parameters including forging temperature, forging speed and different lubricants on the material flow when different contents of Al2O3 were adopted.
This study also discusses the flow status of Al2O3 particles during forging process and the flow mode of the whole blank material. The simulation results indicate that insufficient filling would occur during the forging of an A6061/Al2O3 MMC piston. The die cavity was not completely filled due to lateral overflow of material in the forging process. In order to cope with the insufficient filling problem, this study designed one spew groove between punch and bottom die, preventing the material overflow. The actual forging process was implemented and the features of the forged part were compared with the finite element simulation results. The good agreement between the production part and the finite element simulation results in material flow, forging force and appearance of part profiles confirms the validity of the finite element analysis. The sound production part also indicates that a complex shaped component made of A6061/Al2O3 MMC could be formed by the forging process with proper die design at elevated forming temperature.
Subjects
aluminum-based metal matrix composites
piston
finite element method
Type
thesis
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