Aluminum forging is a key process to achieve high performance of materials. Its process selection directly affects the precision, strength and production cost of parts. In the fields of automobiles, aerospace, etc., the reasonable selection of aluminum forging process has become the core link to enhance product competitiveness. This article will analyze the selection logic of aluminum forging process from the dimensions of material properties, part design, production scale, etc.
一. Core influencing factors of aluminum forging process selection
1. Material properties and process adaptability
Different aluminum alloy forging materials (such as 6061, 7075, 5052, etc.) have significant differences in forgeability, fluidity and heat treatment response. For example:
6061 aluminum alloy has good ductility and is suitable for die forging and extrusion processes;
7075 high-strength aluminum alloy needs to be forged in closed die to avoid cracking;
5052 corrosion-resistant alloy can achieve high-precision forming through cold forging.
The corresponding process parameters need to be matched according to the forging temperature range, deformation resistance and grain control requirements of the material.
2. Part complexity and precision requirements
The selection of aluminum forging process needs to match the part shape, dimensional accuracy and surface quality requirements:
Open die forging is suitable for simple shapes (such as gear blanks), with low cost but limited accuracy;
Closed die forging can manufacture complex cavities (such as automobile control arms), with high accuracy but high mold cost;
Precision forging (such as isothermal forging) can achieve near-net forming of aerospace parts and reduce subsequent processing.
3. Production scale and efficiency
Small batch production: free forging or open die forging is preferred, and the equipment is highly versatile;
Large batch production: closed die forging or multi-station hot forging automation line has more cost advantages, such as large-scale forging of automobile wheels.
二. Classification and typical applications of aluminum forging process
1. Free forging
Features: The blank is pressed by simple tools, with high shape freedom but low accuracy.
Applicable scenarios: aluminum ingot blanking, rough processing of large structural parts (such as aviation frame blanks).
Case: Jiangsu Tiannan Aluminum Forging Co., Ltd. uses free forging to prepare large flange blanks.
2. Die forging
Open die forging: The die only partially constrains the blank, suitable for shaft and disc parts.
Closed die forging: The blank is completely enclosed in the die, suitable for complex shapes (such as engine blades).
Application areas: automobile wheel hub (6061 aluminum alloy closed die forging), aircraft landing gear (7075 aluminum alloy isothermal die forging).
3. Extrusion forging
Features: By combining extrusion and forging, the density and strength of the material are improved.
Typical products: aluminum profiles (such as building door and window frames), high-pressure valve bodies.
Advantages: High material utilization rate, suitable for parts with large aspect ratio.
4. Special forging process
Isothermal forging: carried out under a constant temperature environment, suitable for difficult-to-deform aluminum alloys such as 7075, to ensure uniform grains.
Multi-directional die forging: complex cavities are manufactured by applying pressure in multiple directions, such as aircraft engine turbine disks.
3. Practical Path of Aluminum Forging Process Selection
Clear functional requirements of parts:
Analyze the load conditions of parts (such as automobile wheels need to withstand impact loads) and the use environment (such as the corrosion resistance of marine equipment), and determine key indicators such as material strength and corrosion resistance.
Process-material matching verification:
Predict material flow and stress distribution through simulation software (such as Deform) and optimize process parameters. For example, the closed die forging of 7075 aluminum alloy needs to control the forging temperature at 430-470℃ to avoid overheating.
Cost and efficiency balance:
Compare the mold cost, production cycle and material utilization rate of different processes. For example, although the mold cost of precision forging is high, it can reduce machining time and is suitable for high value-added parts.
Industry standards and compliance:
Follow the process specifications of aerospace (such as AMS standards) and automotive (such as ISO/TS 16949) to ensure product reliability.
4. Future trends of aluminum forging technology
Intelligent process optimization:
Introduce AI algorithm to analyze historical data, dynamically adjust forging parameters, and reduce trial and error costs.
Green process development:
Promote warm forging and cold forging technology to reduce energy consumption; explore the feasibility of forging solid recycled aluminum alloys.
Cross-domain process integration:
Combining additive manufacturing (3D printing) with aluminum forging to achieve integrated manufacturing of complex structures.
The selection of aluminum forging process is a comprehensive reflection of material science, mechanical design and production management. From the flexibility of free forging to the high precision of precision aluminum forging, each process has its unique value. In practical applications, it is necessary to select the most suitable aluminum forging process based on part performance, combined with the company’s equipment capabilities and cost targets. In the future, with the iterative upgrading of process technology, aluminum forging will continue to promote innovative breakthroughs in the field of high-end manufacturing.
