A study of improving warped characteristics during flange forging

The main purpose of this study aims to investigate the warping problems during forging process by FEM simulation and experiments. The parameters considered in this study are die corner radius, ring gap height, type of material, friction condition and surface treatment. Three kinds of aluminum alloys (A2024, A6061 and A7075) are applied to carry out experiments under different conditions to investigate the warping phenomenon and to research the way of improvement. Through a series of simulation and experiments, the following conclusions can be made. First, die corner with chamfer design and taper of ring gap design can improve the warping phenomenon effectively. Second, the larger ring gap height also can improve warp formation. In the case of small ring gap height, larger friction factor between die and billet, and using the material with larger work hardening coefficient can improve warp problem during flange forging. Third, billet with polish treatment in the surface can obtain the best flange outer protruding shape. The results of this study do offer some useful knowledge about the warping problem of flange forging process. Thus, this report will be useful to the academic and relative industries.