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HomeMaterials Science ForumMaterials Science Forum Vol. 1186Process Optimization for Forging an AA6082...

Process Optimization for Forging an AA6082 Automotive Upper Control Arm

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Abstract:

This study examines the forging process of an aluminum upper control arm for automotive applications. To address the geometric complexity and forming challenges, a multi-step forging route, comprising of roll forging, two-stage bending, pre-forging, and final forging, is developed. Finite element analysis (FEA) using DEFORM-3D software is employed to optimize key forming process parameters in the pre‑forging stage. The response surface methodology (RSM), combined with the Box–Behnken design, is utilized to construct predictive models and identify optimal parameter combinations. A successful forged upper control arm is subsequently produced using these optimized forming parameters. The findings demonstrate that integrating FEA with statistical process optimization strengthens the predictive accuracy of the process design and supports defect‑free forging of AA6082 upper control arms.

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Forging and Hot Forming

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Periodical:

Materials Science Forum (Volume 1186)

Pages:

59-72

DOI:

https://doi.org/10.4028/p-ir99uX

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Online since:

April 2026

Authors:

Li Ju Zhou, Lei Gang Wang, Ming Xiao Shi, Angela Daniela La Rosa, Elisabete F. Reia da Costa, Xiang Ma*

Keywords:

AA6082, Automotive Control Arm, Die Design, Finite Element Analysis, Forging, Response Surface Methodology, Rolling

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Creative Commons CC BY 4.0

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* - Corresponding Author

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