Precise Forming of Complex Magnesium Alloy Components Based on Finite Element Method and Quantitative Preforming Design
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JMEPEG https://doi.org/10.1007/s11665-020-05014-2
Precise Forming of Complex Magnesium Alloy Components Based on Finite Element Method and Quantitative Preforming Design Xubin Li, Henry Hu, Zhimin Zhang, Yongbiao Yang, and Qiang Wang (Submitted March 20, 2020; in revised form July 20, 2020) To solve the difficulties associated with integral precise extrusion forming for complex components of magnesium alloy, Deform-3D finite element simulation software was used to conduct numerical analyses for the forming process. Different extrusion schemes were used for determining the overall extrusion difficulties associated with special-shaped thin-walled complex components of magnesium alloy. The effects of a preformed blank on the filling and formation of folding defects in the forming process were studied. Based on the principle of minimum energy in the process of plastic deformation and the law of least resistance, volume predistribution and equal distance flow quantitative compensation methods were put forward. These methods were used to optimize the size and structure of the preform, forming a uniform material flow distribution. They also enabled one to manifest a uniform material flow velocity distribution, reduce the forming load, and avoid the creation of folding and filling defects during the final forming, for the realization of an efficient and reliable preform optimization design for magnesium alloy profiled complex components. The results obtained from a forming test, microstructure and mechanical properties test showed that the mechanical properties of the extruded component all met the service indexes. This design method can provide a theoretical reference for preforming design of profiled complex components. Keywords
complex components, FEM, preforming, quantitative design
magnesium
alloy,
1. Introduction To meet the requirements for a lightweight component in the aerospace, transportation, and other fields, a large number of key components adopt a complex structure based on a specialshaped thin wall with high reinforcement, which leads to more demanding requirements in terms of component size, shape, weight and performance. The projected cross-section of a magnesium alloy component with a special-shaped thin wall is non-axisymmetric. The webs and sidewalls of such a component are thin, and its interior contains complex structural features such as a high bar. These complex structural features lead to a lightweight component, but become more difficult to manufacture at the same time. Due to a low utilization rate for raw materials, long production cycles, high cost and poor mechanical properties, it is difficult to use traditional processing technologies such as steel plate welding, forging and casting to meet user demand (Ref 1-3). Precise extrusion forming can meet the service index for this kind of component, but due to its structural complexity, the preform size and shape have a great impact on the final forming
Xubin Li, Zhimin Zhang, Yongbiao Yang, and Qiang Wang, School of Materials Science and Engineering, North
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