Study on Cold Forging Process Design for Automotive Components of Al 6061 Alloys

Study on Cold Forging Process Design for Automotive Components of Al 6061 Alloys
  IJETT-book-cover           
  
© 2024 by IJETT Journal
Volume-72 Issue-5
Year of Publication : 2024
Author : Sung-Nam Park, Jyun-Pyo Hong, Jung-Woo Song, Jong-Hun Kang
DOI : 10.14445/22315381/IJETT-V72I5P112

How to Cite?

Sung-Nam Park, Jyun-Pyo Hong, Jung-Woo Song, Jong-Hun Kang, "Study on Cold Forging Process Design for Automotive Components of Al 6061 Alloys," International Journal of Engineering Trends and Technology, vol. 72, no. 5, pp. 113-119, 2024. Crossref, https://doi.org/10.14445/22315381/IJETT-V72I5P112

Abstract
The present study was conducted to develop forgings for automobiles by increasing the cold forging formability of the Al6061 material. Heat treatment was performed at the temperatures of 350°C, 375°C, 400°C, 425°C, 450°C, 475°C, and 500°C to evaluate the formability of the raw material depending on the heat treatment conditions. Tensile test specimens were prepared for each heat treatment condition, and their tensile strength, yield strength, and elongation were measured through a tensile test. The test results showed that the maximum elongation and the minimum yield strength, indicative of the highest formability, were found at 400°C. The flow stress and fracture damage were calculated by using the displacement-load relationship obtained from the tensile test. Multi-stage forging process was designed, and forming process analysis was performed. In the forming analysis of products with a large flange and a small thickness, a value equal to or less than the limiting damage was predicted. A prototype forming was performed through the designed forging process, and as predicted by the finite element analysis, no forging defect occurred. It was confirmed that in the forging process with a large amount of deformation, forming limits can be increased through heat treatment of raw materials, and defects can be avoided.

Keywords
Aluminum alloys, Annealing treatment, Flow stress, Cold forging, Forging defects, Finite element analysis.

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