Multi-stage Cold Forging of Thin-walled Components

The bulk forming process of sheet metal has a high potential for the near-net–shape forming of metal components with thin wall thickness. However, the main critical challenges in this process are the high forming pressure and the difficulties in the control of metal flow in lateral or radial direction which are caused by the compression of thin workpiece in its thickness direction. In the present study, the multi-stage cold forging process was introduced to address the current challenges in the forming of thin-walled metal components with multiple wall thicknesses. The case studies were conducted through FE simulation and experiments and the results showed that this process is effective to reduce the forming load and improve the radial metal flow in the forming of two kinds of thin aluminium alloy components with multi thicknesses.