Spinning-punch new technology for aluminum alloy plate-wheels forming
The aluminium alloy plate-wheels are a new kind of wheels with light-weight, energy-saving and environmental protection. Spinning is a conventional technology to form aluminium alloy plate-wheels, but the outline dimension and run-out of rolled lip in end face are difficult to meet the exacting requirements of wheels blueprint. So the new spinning-punch forming technology for aluminium alloy plate-wheels was researched and simulated. 3-D elastic-plastic finite element models were constructed and appropriate boundary conditions were given out. The results show that aluminium alloy plate-wheels with good quality can be formed by spinning-punch forming technology through controlling roller feed rate, roller'diameter, flanging times, and punching stroke, etc. And the relationships between spinning load and roller'diameter, rolled lip forming quality and flanging times are found.
An analysis of the forging processes for 6061 aluminum-alloy wheels
Abstract The metal forming processes of aluminum-alloy wheel forging at elevated temperatures are analyzed by the finite element method. A coupled thermo-mechanical model for the analysis of plastic deformation and heat transfer is adapted in the finite element formulation. In order to consider the strain-rate effects on material properties and the flow stress dependence on temperatures, the rigid visco-plasticity is applied to the simulation. Several process conditions were applied to the simulation such as punch speed, rim thickness, and the depth of die cavity. Experiment for a simplified small-scale model is carried out and compared with the simulation in terms of forging load to verify the validity of the formulation adapted in this study. Then, various processes with full-scale model for a 6061 aluminum-alloy wheel are simulated. Material flow, pressure distributions exerted on the die wall, temperature distributions and forging loads are summarized as basic data for process design and selection of a proper press equipment.
Automotive component failures
Abstract The failure of vehicle components is an area which is likely to affect all of us at one stage or another. In this paper the distribution of component failures is discussed, as well as the causes thereof. Four case studies are presented to give insight in the methodology of failure analysis of automotive components, and the valuable information which can be gained thereby.