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Precise Forming of Complex Magnesium Alloy Components Based on Finite Element Method and Quantitative Preforming Design

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Abstract

To solve the difficulties associated with integral precise extrusion forming for complex components of magnesium alloy, Deform-3D finite element simulation software was used to conduct numerical analyses for the forming process. Different extrusion schemes were used for determining the overall extrusion difficulties associated with special-shaped thin-walled complex components of magnesium alloy. The effects of a preformed blank on the filling and formation of folding defects in the forming process were studied. Based on the principle of minimum energy in the process of plastic deformation and the law of least resistance, volume predistribution and equal distance flow quantitative compensation methods were put forward. These methods were used to optimize the size and structure of the preform, forming a uniform material flow distribution. They also enabled one to manifest a uniform material flow velocity distribution, reduce the forming load, and avoid the creation of folding and filling defects during the final forming, for the realization of an efficient and reliable preform optimization design for magnesium alloy profiled complex components. The results obtained from a forming test, microstructure and mechanical properties test showed that the mechanical properties of the extruded component all met the service indexes. This design method can provide a theoretical reference for preforming design of profiled complex components.

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Acknowledgments

The authors would like to gratefully acknowledge the support of the National Natural Science Foundation of China (51675492) and Natural Science Foundation of Shanxi Province (201801D121106)

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Authors and Affiliations

  1. School of Materials Science and Engineering, North University of China, Taiyuan, 030051, China

    Xubin Li, Zhimin Zhang, Yongbiao Yang & Qiang Wang

  2. Department of Mechanical, Automotive and Materials Engineering, University of Windsor, Windsor, N9B 3P4, Canada

    Henry Hu

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  1. Xubin Li
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  2. Henry Hu
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Correspondence to Xubin Li.

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Li, X., Hu, H., Zhang, Z. et al. Precise Forming of Complex Magnesium Alloy Components Based on Finite Element Method and Quantitative Preforming Design. J. of Materi Eng and Perform 29, 5139–5146 (2020). https://doi.org/10.1007/s11665-020-05014-2

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  • DOI: https://doi.org/10.1007/s11665-020-05014-2

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