TY - JOUR

T1 - Analysis of Material Characteristics and Forging Parameters for Flashless Forged Aluminum-Matrix Composites

AU - Stonis, Malte

AU - Rüther, Tilmann

AU - Behrens, Bernd Arno

N1 - Funding information: FUNDING T he authors thank the German Research Foundation (DFG) for the financial funding for the accomplishment of the research project.

PY - 2014/3/4

Y1 - 2014/3/4

N2 - 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.

AB - 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.

KW - Aluminum

KW - Characterization

KW - Composite

KW - FEA

KW - Flashless

KW - Forging

KW - Matrix

KW - Simulation

KW - Tool

KW - Upsetting

UR - http://www.scopus.com/inward/record.url?scp=84896764938&partnerID=8YFLogxK

U2 - 10.1080/10426914.2013.822986

DO - 10.1080/10426914.2013.822986

M3 - Article

AN - SCOPUS:84896764938

VL - 29

SP - 140

EP - 145

JO - Materials and Manufacturing Processes

JF - Materials and Manufacturing Processes

SN - 1042-6914

IS - 2

ER -