Numerical and Experimental Studies on Extrusion of Fan-Shaped Shell of Magnesium Alloy

Bao Hong Zhang; Yao Jin Wu; Zhi Min Zhang

doi:10.4028/www.scientific.net/AMR.626.381

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Numerical and Experimental Studies on Extrusion of Fan-Shaped Shell of Magnesium Alloy

Abstract:

This paper presents a case study of optimizing the forming process for a fan-shaped shell component. Numerical simulation was used to study the backward extrusion process of a fan-shaped shell. The underfill defect produced at the opening of the extruded shell due to the billet shape was solved and the minimal base thickness required to avoid the presence of the underfill defect at the bottom corner of the component was defined through the numerical simulation. The extrusion drawing and forming process of the fan-shaped shell were designed on the basis of the results of the numerical simulation. Forming experiments had been performed on the fan-shaped shell at 380 °C and cracking was found on the outside wall in the center of the extruded shell. Choked groove on the inner wall of the die and reducing the lubrication had been used to avoid the presence of cracking. The fan-shaped shell of AZ31 magnesium alloy has been successfully formed by the three-stage forming process of hot upsetting, hot backward extrusion and cold sizing.