Thermo-mechanically coupled numerical and experimental study on 7075 aluminum forging process and dies

Özcan, Mehmet Cihat
Combination of high strength with light weight which is the prominent property of aluminum alloy forgings has led aluminum forgings used in rapidly expanding range of applications. In this study, to produce a particular 7075 aluminum alloy part, the forging process has been designed and analyzed. The forging process sequence has been designed by using Finite Volume Method. Then, the designed process has been analyzed by using Finite Element Method and the stress, strain and temperature distributions within the dies have been determined. Five different initial temperatures of the billet; 438, 400, 350, 300 and 250 degree Celsius have been considered in the thermo-mechanically coupled simulations. The initial temperatures of the dies have been taken as 200 degree Celsius for all these analyses. Finite volume analysis and finite element analysis results of the preform and finish part have been compared for the initial billet temperature of 400 oC. Close results have been observed by these analyses. The experimental study has been carried out for the range of the initial billet temperatures of 251442 degree Celsius in METU-BILTIR Center Forging Research and Application Laboratory. It has been observed that the numerical and the experimental results are in good agreement and a successful forging process design has been achieved. For the initial die temperature of 200 degree Celsius, to avoid the plastic deformation of the dies and the incipient melting of the workpiece, 350 degree Celsius is determined to be the appropriate initial billet temperature for the forging of the particular part.


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Citation Formats
M. C. Özcan, “Thermo-mechanically coupled numerical and experimental study on 7075 aluminum forging process and dies,” M.S. - Master of Science, Middle East Technical University, 2008.