A swage die and forming method for a curved Y-shaped aluminum alloy forging

Abstract

The application belongs to the technical field of aluminum alloy plastic forming, and particularly relates to a die forging die and a forming method of a bent Y-shaped aluminum alloy forging. The die forging die comprises an upper die and a lower die, and a cavity matched with the shape of the bent Y-shaped aluminum alloy forging is formed between the upper die and the lower die. The upper die is provided with cavities for forming an A-shaped boss and a cylindrical boss. The lower die corresponding to the curved turning part is provided with a head process boss, and the shape of the head process boss is a circular arc. The lower die corresponding to the position of the cylindrical boss is provided with a branch process boss, and the shape of the branch process boss is a circular arc. The application reduces the weight of the blank, reduces the forging pressure, and improves the deformation uniformity.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of plastic forming of aluminum alloy, and particularly relates to a die forging die and a forming method of a bent Y-shaped aluminum alloy forging. BACKGROUND

[0002] Many aluminum alloy forgings are used on automobile parts, among which the bent Y-shaped aluminum alloy forging is generally formed by free forging or simple blanking die forging due to its complex shape and difficulty in blanking.

[0003] When free forging is formed, the stability of the forging product is poor, and the machining amount of the final part is large, which wastes raw materials.

[0004] When simple blanking die forging is formed, in order to ensure that the forging is filled perfectly and deformed uniformly, the blank weight has to be increased, which causes most of the raw materials to flow to the burr during the forming process, resulting in serious waste of raw materials and uneven deformation. SUMMARY

[0005] The technical problem to be solved by the present application is to provide a die forging die and a forming method of a bent Y-shaped aluminum alloy forging, which reduces the blank weight, reduces the forging pressure, and improves the deformation uniformity.

[0006] The embodiment of the present application provides a die forging die of a bent Y-shaped aluminum alloy forging, the bent Y-shaped aluminum alloy forging is in a Y shape as a whole, comprises a head and two arms, an A-shaped boss is arranged on the upper surface of the head, a cylindrical boss is arranged on the upper surface of the arm, and the lower surface of the bent Y-shaped aluminum alloy forging is in a curved arc shape as a whole, and the turning point of the arc is located at the head.

[0007] The die forging die comprises an upper die and a lower die, and a cavity matched with the shape of the bent Y-shaped aluminum alloy forging is formed between the upper die and the lower die.

[0008] The upper die is provided with cavities for forming the A-shaped boss and the cylindrical boss.

[0009] The lower die corresponding to the turning point of the arc is provided with a head process boss, and the shape of the head process boss is a circular arc.

[0010] The lower die corresponding to the position of the cylindrical boss is provided with an arm process boss (the arm process boss extends in the arm direction), and the shape of the arm process boss is a circular arc with a radius not less than 15 mm.

[0011] The lower die corresponding to the position of the cylindrical boss is provided with a support arm process boss, that is, the support arm process boss is provided on the lower die, and the position of the support arm process boss on the lower die corresponds to the position of the cylindrical boss on the upper die, so that the two surfaces of the curved Y-shaped aluminum alloy forging are formed with corresponding support arm process bosses and cylindrical bosses respectively.

[0012] Preferably, the number of head process bosses is 3.

[0013] Preferably, the radius of the circular arc of the head process boss is 15-40mm, and the radius of the circular arc of the three head process bosses decreases in turn from the head to the support arm.

[0014] Preferably, the radius of the circular arc of the three head process bosses is 30-40mm, 20-22mm and 15-18mm respectively from the head to the support arm.

[0015] Preferably, the central angles corresponding to the circular arcs are 70-80°, 120-140° and 35-45° respectively.

[0016] Preferably, the distance between the three head process bosses is 4mm, and the fillet between the three head process bosses and between the head process boss and the lower die is 4mm.

[0017] Preferably, the radius of the circular arc of the support arm process boss is 10mm, and the fillet between the support arm process boss and the lower die is 5mm.

[0018] The embodiment of the present application provides a forming method of a curved Y-shaped aluminum alloy forging, which comprises the following steps,

[0019] The square billet is forged into a Y-shaped billet by a blanking die;

[0020] The Y-shaped billet is placed in the die forging die, and is forged to obtain the curved Y-shaped aluminum alloy forging.

[0021] Preferably, the weight ratio of the square billet to the Y-shaped billet is 1-1.1:1.

[0022] Preferably, the thickness ratio of the Y-shaped billet to the curved Y-shaped aluminum alloy forging is 1.1-1.4:1, and the length ratio of the Y-shaped billet to the curved Y-shaped aluminum alloy forging is 0.7-0.9:1.

[0023] The present application has the beneficial effects that, by performing the shape following design on the final forging Y-shaped billet during the forming of the Y-shaped curved forging, the weight of the forging blank can be greatly reduced, and the equipment pressure during forging can be greatly reduced. The Y-shaped billet is formed by die forging, which improves the size consistency of the billet and the stability of the forging.

[0024] The present application re-designs the die, increases the process boss at the corresponding position of the die aiming at the weak deformation area of the forged piece, and the blank first contacts the process boss in the die cavity during the forming process, so that the surface of the blank first deforms and flows to the surrounding, and the deformation of the surface of the forged piece is improved, so that the deformation of the whole forged piece is more uniform. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 It is a structure schematic view of the bent Y-shaped aluminum alloy forged piece, wherein (a) is a lateral top view structure schematic view, and (b) is a lateral bottom view structure schematic view.

[0026] Figure 2 It is a side view and a partial enlarged view of the die forging die, wherein (a) is a side view of the die forging die, and (b) is a partial enlarged view of the process boss.

[0027] Figure 3 (a) is a structure schematic view of the lower die of the die forging die; Figure 3 (b) is Figure 3 (a) is a structure schematic view of the section one.

[0028] Figure 4 It is a size view of the Y-shaped blank.

[0029] Figure 5 It is a structure schematic view of the blanking die of the Y-shaped blank.

[0030] Figure 6 It is an equivalent plastic strain equivalent nephogram of the Y-shaped aluminum alloy forged piece of Example 1, wherein (a) is a Y-shaped aluminum alloy forged piece structure, (b) is an equivalent plastic strain and an equivalent nephogram of section one in (a), and (c) is an equivalent plastic strain and an equivalent nephogram of section two in (a).

[0031] Figure 7 It is a structure schematic view of the die of Comparative Example 2-3.

[0032] Figure 8 It is a size view of the simple blank of Comparative Example 2.

[0033] Figure 9 It is an equivalent plastic strain equivalent nephogram of the Y-shaped aluminum alloy forged piece of Comparative Example 2, wherein (a) is a Y-shaped aluminum alloy forged piece structure of Comparative Example 2, (b) is an equivalent plastic strain and an equivalent nephogram of section one in (a), and (c) is an equivalent plastic strain and an equivalent nephogram of section two in (a).

[0034] Figure 10Equivalent plastic strain cross section and contour of the Y-shaped aluminum alloy forging of Comparative Example 4. Wherein (a) is the structure of the Y-shaped aluminum alloy forging of Comparative Example 4, (b) is the equivalent plastic strain and equivalent contour of cross section one in (a), (c) is the equivalent plastic strain and equivalent contour of cross section two in (a).

[0035] Figure 11 The structure schematic diagram of the die and the structure schematic diagram of the cross section of Comparative Example 4. Wherein (a) is the structure schematic diagram of the die side of Comparative Example 4, (b) is the local enlarged view of the process boss in (a), (c) is the structure schematic diagram of the die, (d) is the structure schematic diagram of cross section one in (c).

[0036] Figure 12 Equivalent plastic strain cross section and contour of the Y-shaped aluminum alloy forging of Comparative Example 4. Wherein (a) is the structure of the Y-shaped aluminum alloy forging of Comparative Example 4, (b) is the equivalent plastic strain and equivalent contour of cross section one in (a), (c) is the equivalent plastic strain and equivalent contour of cross section two in (a).

[0037] Figure 13 The structure schematic diagram of the die and the structure schematic diagram of the cross section of Comparative Example 5. Wherein (a) is the structure schematic diagram of the die side of Comparative Example 5, (b) is the local enlarged view of the process boss in (a).

[0038] Figure 14 Equivalent plastic strain cross section and contour of the Y-shaped aluminum alloy forging of Comparative Example 5. Wherein (a) is the structure of the Y-shaped aluminum alloy forging of Comparative Example 5, (b) is the equivalent plastic strain and equivalent contour of cross section one in (a), (c) is the equivalent plastic strain and equivalent contour of cross section two in (a).

[0039] Figure 2 、 3 , the units of the radius and length marked in 4, 8, 11, 13 are mm.

[0040] In the figure, 1 is a curved Y-shaped aluminum alloy forging, 101 is an upper surface, 102 is an A-shaped boss, 103 is a cylindrical boss, 104 is a lower surface, 105 is a head, 106 is an arm;

[0041] 2 is a Y-shaped blank, 3 is an upper die, 4 is a lower die, 401 is a head process boss, 402 is an arm process boss;

[0042] 5 is a convex die, 6 is a concave die, 7 is a ejector pin. DETAILED DESCRIPTION

[0043] Example 1

[0044] As Figures 1-3As shown, a swage die for a curved Y-shaped aluminum alloy forging, the curved Y-shaped aluminum alloy forging is Y-shaped as a whole, including a head 105 and two arms 106, the upper surface 101 of the head 105 is provided with an A-shaped boss 102, the upper surface of the arm 106 is provided with a cylindrical boss 103, the lower surface of the curved Y-shaped aluminum alloy forging is curved as a whole, and the turning point of the arc is located at the head;

[0045] The swage die includes an upper die 3 and a lower die 4, and a cavity matching the shape of the curved Y-shaped aluminum alloy forging is formed between the upper die 3 and the lower die 4;

[0046] The upper die 3 is provided with a cavity for forming the A-shaped boss 102 and the cylindrical boss 103;

[0047] The lower die 4 corresponding to the turning point of the arc is provided with a head process boss 401, and the shape of the head process boss 401 is a circular arc;

[0048] The lower die 4 corresponding to the position of the cylindrical boss 103 is provided with an arm process boss 402 extending in the arm direction, and the shape of the arm process boss 402 is a circular arc.

[0049] Figure 1 It is a structural schematic view of the curved Y-shaped aluminum alloy forging, and the parting surface is located at the upper surface 101 of the forging.

[0050] The number of head process bosses 401 is three. The radius of the circular arc of the head process boss 401 is 15-40mm, and the radius of the circular arc of the three head process bosses 401 decreases in the direction from the head 105 to the arm 106, which is R35mm, R20mm and R17.5mm respectively, and the central angles are 73°, 130° and 41° respectively. When the processing allowance of the forging is not affected, the process boss at this position can be set according to the maximum radius. If the radius of the head process boss 401 is too small, the effect of extrusion is not sufficient when the blank contacts the head process boss 401 during swaging, which affects the uniformity of deformation.

[0051] The distance between the three head process bosses 401 is 4mm, and the fillet between the three head process bosses 401 and the lower die is 4mm.

[0052] The radius of the circular arc of the arm process boss 402 is 10mm, and the fillet between the arm process boss 402 and the lower die 4 is 5mm.

[0053] As shown in the figure, Figures 2-3As shown, other recesses (i.e. cavities) on the lower die 4 except the head process boss 401 and the arm process boss 402 belong to the existing recesses in the die for preparing the Y-shaped aluminum alloy forging, which are designed as the prior art. For the Y-shaped aluminum alloy forging of a certain size, the depth, length and width of the cavity are determined.

[0054] Embodiment 2

[0055] A forming method of a curved Y-shaped aluminum alloy forging, comprising the steps of,

[0056] forging the square billet into a Y-shaped billet by a blanking die;

[0057] placing the Y-shaped billet into the die forging die of Embodiment 1, and forging to obtain the curved Y-shaped aluminum alloy forging.

[0058] The weight ratio of the square billet and the Y-shaped billet is 1-1.1:1.

[0059] The thickness ratio of the Y-shaped billet and the curved Y-shaped aluminum alloy forging is 1.1-1.4:1, and the length ratio of the Y-shaped billet and the curved Y-shaped aluminum alloy forging is 0.7-0.9:1.

[0060] Specifically, taking the 7075 aluminum alloy automobile forging as the Y-shaped curved forging, the weight of the forging is 9.156 kg, and the outer dimension of the forging is 444.6 mm x 303.8 mm x 69.3 mm as an example, the detailed forming method is described.

[0061] 1. Design of curved Y-shaped aluminum alloy forging

[0062] In order to reduce the machining allowance of the forging, a curved parting surface is used, and a part (i.e. the upper surface 101) is provided with two cylindrical bosses 103 and one irregular A-shaped boss 102 with grooves, and the other part (i.e. the lower surface 104) is a Y-shaped curved part. The above two parts constitute the forging, and the draft angle of the forging is set to 3°.

[0063] The concave fillet between the concave die in the irregular A-shaped boss 102 with grooves and the parting surface is set to R10 mm, the concave fillet between the outer contour of the A-shaped boss 102 and the parting surface is set to R15 mm, and the remaining convex fillets are set to R5 mm.

[0064] The concave fillet between the cylindrical boss 103 and the parting surface is set to R10 mm, and the convex fillet is set to R5 mm.

[0065] The corner in the lower surface 104 is set to R10 mm, and the convex fillet is set to R5 mm.

[0066] 2. Design of forging dies for Y-shaped bending forgings.

[0067] To facilitate the placement and forming of the billet during forging, the lower surface 104 is placed on the lower die 4, and two cylindrical bosses 103 and one irregularly shaped A-shaped boss 102 with a groove are placed on the upper die 3. Figure 2 As shown.

[0068] To reduce the weak deformation zone at the lowest position of the forging head, three head process bosses 401 are set in the lower die 4. The head process bosses 401 are circular, and the radii of the three head process bosses 401 are set to R35mm, R20mm and R17.5mm respectively, with central angles of 73°, 130° and 41° respectively. The spacing between the head process bosses 401 is set to 4mm, and the fillets between the head process bosses 401 and between the head process bosses 401 and the lower die 4 are set to 4mm.

[0069] To address the weak deformation areas on the two support arms 106 of the forging, a curved support arm process boss 402 is provided in the lower die 4 at the positions of each of the two support arms 106, as shown below. Figure 3 As shown, the radius of the support arm process boss 402 is set to R10mm, and the fillet between the support arm process boss 402 and the lower mold 4 is set to R5mm.

[0070] 3. Design of Y-shaped billet 2.

[0071] The thickness H of the Y-shaped blank 2 Y字形坯料 With respect to the effective thickness dimension H of the forging 锻件 The ratio should be between 1.1 and 1.4, that is, 1.1 < H. Y字形坯料 / H 锻件 <1.4.

[0072] The length L of the Y-shaped blank Y字形坯料 With the length dimension L of the forging 锻件 The ratio should be between 0.7 and 0.9, that is, 0.7 < L "Y" shaped billet / L forging < 0.9.

[0073] The maximum width dimension T of the Y-shaped billet Y字形坯料 With the maximum width dimension T of the forging 锻件 The ratio should be between 0.6 and 1.0, that is, 0.6 < T. Y字形坯料 / T 锻件 <1.0.

[0074] The remaining shapes should be designed according to the shape of the forging, and the cross-sectional area S at the corresponding position of the Y-shaped billet should be... Y字形坯料 Cross-sectional area S at the corresponding position of the forging 锻件 The ratio should be between 1.1 and 1.3, that is, 1.1 < S Y字形坯料 / S 锻件< 1.3.

[0075] In this embodiment, the effective thickness H of the forged piece 锻件 is 62.5 mm, the thickness H of the Y-shaped blank is designed to be 80 mm; the length dimension L of the forged piece Y字形坯料 is 444.6 mm, the length dimension L of the Y-shaped blank is designed to be 370 mm; the maximum width dimension T of the forged piece 锻件 is 303.8 mm, the width dimension T of the Y-shaped blank is designed to be 227.6 mm; the remaining dimensions of the Y-shaped blank are shown in Table 1. Y字形坯料 锻件 Y字形坯料 Figure 4 The weight of the Y-shaped blank is about 10.2 Kg.

[0076] 4. Design of the blanking die for the Y-shaped blank.

[0077] The Y-shaped blank is difficult to be directly forged by free forging, and a simple blanking die is designed to blank the blank, the blank size is more accurately controlled by using the die blanking, and the difficulty of on-site forging is reduced, which helps to improve the size stability of the blank and the batch stability of the final forged product. The simple blanking die is shown in Fig. 2. Figure 5 The simple blanking die includes a punch 5, a recessed die 6, and a top rod 7.

[0078] 5. Design of the square blank.

[0079] Since the Y-shaped blank 2 is obtained by the blanking die, the blank used by the Y-shaped blanking die is designed as a square blank, which is easy to prepare and has low accuracy requirements, and can be directly obtained by free forging.

[0080] The weight G of the square blank 方坯料 should be between 1.0 and 1.1 times the weight G of the Y-shaped blank Y字形坯料 , that is, 1.0 < G 方坯料 / G Y字形坯料 < 1.1.

[0081] Meanwhile, the thickness dimension H of the square blank 方坯料 should be slightly smaller than the thickness dimension H of the Y-shaped blank Y字形坯料 , and the width dimension T of the square blank 方坯料 should be smaller than the width dimension T of the Y-shaped blank Y字形坯料 .

[0082] In this embodiment, the weight G of the Y-shaped blank Y字形坯料 is 10.2 Kg, the weight G of the square blank 方坯料 is designed to be 10.63 Kg, the thickness dimension H of the Y-shaped blank Y字形坯料 is 80 mm, the thickness dimension H of the square blank 方坯料 is designed to be 72 mm, and the width dimension T of the Y-shaped blank​​​Y字形坯料 230mm, the length dimension of the square billet is L 方坯料 230mm; according to G 方坯料 230mm, H 方坯料 230mm, and T 方坯料 230mm. 方坯料 230mm.

[0083] 6. Blank design.

[0084] The blank volume is calculated according to the nominal dimension of the square billet H 方坯料 230mm, T 方坯料 230mm, and L 方坯料 230mm, plus the volume after adding proper adjustment tolerance. The nominal dimension volume of the square billet is V 方坯料 =230x230x76=4020400mm 3 The adjusted blank volume V 下料 =V 方坯料 x1.05 (adjustment tolerance coefficient)=4020400x1.05=4221420mm 3 The diameter of the ingot is selected as 150mm, and the length is calculated as 240mm, G 下料 is 11.9Kg.

[0085] 7. Product production process design

[0086] The various materials used in the product production process are obtained by using the designs 1-6 above, and the product production process is as follows:

[0087] Blanking→square billet forging (free forging)→Y-shaped billet forging (die forging)→Y-shaped bending type forging (die forging).

[0088] Specifically:

[0089] Blanking: using a band saw to cut the ingot after the car to blank according to the blanking size Φ150mmx240mm;

[0090] Square billet forging: using a heating to 450℃ upper and lower anvil to perform free forging on the billet heated to 450℃, and forming the multi-directionally forged ingot according to the lengthxwidthxheight of 230mmx230mmx76mm;

[0091] Y-shaped billet forging: using a Y-shaped billet die (i.e. a simple die, as shown in Figure 5 ) heated to 450℃ to perform die forging on the square billet heated to 450℃, and the outer contour size of the Y-shaped billet after forging is 370mmx277.6mmx80mm, and the remaining dimensions are shown in Figure 4 ;

[0092] Y-shaped bending type forging: the Y-shaped blank heated to 450 DEG C is placed in a Y-shaped bending type forging die (i.e. the die forging die of Example 1) heated to 450 DEG C for die forging.

[0093] After the forging is designed and produced by the method of the application, the blank weight is 11.9 Kg, the maximum forging pressure of the forging produced by the method of the application is only 3920 tons, and the deformation of the forging is relatively uniform, without obvious weak deformation area. The equivalent plastic strain cloud map of the forging is shown in Figure 6 Two sections of the forging are intercepted, and the equivalent plastic strain of the forging after forming is between 0.55 and 1.20, and the deformation amount is between 42.3% and 69.9%, and the deformation of the forging is relatively uniform.

[0094] The forging of the application is also machined after die forging, and the recesses forged by the head process boss 401 and the arm process boss 402 are removed during subsequent product machining, so the surface of the forging at the above-mentioned position is a smooth surface.

[0095] Comparative Example 1

[0096] A cuboid forging is directly forged by free forging, and then machined to the size of the part by machining, which does not need to use a special die and is formed by using the flat anvil of the forging equipment. When the product is designed by free forging, due to the instability of free forging, the machining allowance is larger than that of die forging, and the design size of the free forging is (465±10) mm×(324±10) mm×(80±5) mm, and the nominal size of the forging is about 33.7 Kg. The blank size is: Φ200 mm×410 mm, and the blank weight is about 36 Kg.

[0097] The forging process route is: first, the bar stock is drawn to 169 mm×169 mm×450 mm along the Z direction (axial direction), then upset to 180 mm along the Z direction, then drawn and upset along the X and Y directions once respectively according to the above-mentioned size, and finally drawn and shaped to (465±10) mm×(324±10) mm×(80±5) mm along the Z direction.

[0098] This type of forging has too large machining allowance, and the material utilization rate is extremely low. Compared with Example 2, the size stability of the forging is poor due to the influence of the experience and method of the operator, and the blank weight of the forging is about 36 Kg, and the material utilization rate is low.

[0099] Comparative Example 2

[0100] In order to reduce the weight of the blank of the forging, a simple blank is designed for die forging, which can reduce the weight of the blank to a certain extent, but causes the forging equipment to be too large, and because the cross-sectional area of the corresponding position of the simple blank is larger than that of the corresponding position of the forging, the deformation of the forging is too large, which has an adverse effect on the performance of the forging.

[0101] The difference between Comparative Example 2 and Example 2 is that the simple blank and the die are different. Specifically, compared with Example 2, Comparative Example 2 is different in that:

[0102] 1) The size diagram of the simple blank is shown in Figure 8 , and the Y-shaped blank in Example 2 is replaced by the simple blank.

[0103] 2) When the Y-shaped bending type forging in Example 2 is forged, the die forging die in Example 1 is not used, but the die as shown in Figure 7 is used, and the die as shown in Figure 7 is used. Compared with the die forging die in Example 1, the difference is that the head process boss 401 and the arm process boss 402 are not set.

[0104] The rest is the same as Example 1.

[0105] The weight of the simple blank is 16.8 Kg, and the weight of the blank is 18.5 Kg. When the forging is under-pressed by 3.8 mm, the maximum pressure of the forging equipment reaches 120 MN, and the die forging stops at this time. At this time, the equivalent plastic strain cloud map of the forging is shown in Figure 9 , and two sections of the forging are intercepted. After the forging is formed, the equivalent plastic strain is between 0.84 and 6.29, and the deformation is between 56.8% and 99.8%. The overall deformation of the forging is too large, which will have an adverse effect on the performance of the forging.

[0106] Compared with the free forging forming of Example 2, the weight of the blank is reduced by 24.1 Kg, which is reduced by 66.9%. Compared with the die forging forming of Comparative Example 2, the weight of the blank is reduced by 4.9 Kg, which is reduced by 26.5%.

[0107] Comparative Example 3

[0108] Comparative Example 3 is different from Example 2 in that the head process boss 401 and the arm process boss 402 are not set in the lower die 4, and the rest is the same as Example 1.

[0109] The schematic diagram of the die is shown in Figure 7 , Figure 10The figure shows the equivalent strain cloud diagram of the forging after it is fully formed. As can be seen from the figure, the overall equivalent plastic strain of the forging is 0.24~1.35. There are areas with weak deformation in the large end and long arm parts of the forging, with a strain of only 0.24. The overall deformation of the forging is very uneven during the forming process, resulting in a large difference in the performance of different parts of the forging.

[0110] In this comparative example, the lower mold cavity in the weak deformation zone is arc-shaped. When the billet comes into contact with the cavity, the billet is resisted as it flows downward. The billet undergoes upsetting deformation and flows to the surrounding areas. As a result, some areas on the surface of the billet are most affected by friction and the cooling effect of the mold cavity. The deformation temperature is low and the deformation resistance is greater than in other areas, making deformation the most difficult.

[0111] Comparative Example 4

[0112] The difference between Comparative Example 4 and Example 2 is that the head process boss 401 and the support arm process boss 402 in the lower mold 4 are square, while the rest are the same as in Example 2.

[0113] See mold diagram Figure 11 , Figure 12 This is an equivalent strain contour plot of the forging after it has been fully formed, as shown in the figure. The overall equivalent plastic strain of the forging is 0.21~1.25. There are areas of weak deformation in the large end and long arm sections of the forging, with a strain of only 0.21. The overall deformation of the forging is also uneven during the forming process, resulting in significant differences in performance between different parts of the forging. In this comparative example, the lower mold cavity in the weak deformation area is a square recessed boss. When the billet is pressed downwards, it directly contacts the surface of the square recessed boss, causing the billet to flow outwards. Furthermore, deformation in this area is relatively difficult, resulting in a lower degree of deformation.

[0114] Comparative Example 5

[0115] The difference between Comparative Example 5 and Example 2 is that the radius of the head process boss 401 set in the lower mold 4 is different. In this comparative example, the arc radii are R25mm, R15mm, and R10mm, and the central angles are 88°, 126°, and 55°, respectively; the rest is the same as Example 2.

[0116] See mold diagram Figure 13 , Figure 14 This is an equivalent strain contour plot of the forging after it has been fully formed in this comparative example. As can be seen from the figure, the overall equivalent plastic strain of the forging is 0.20~1.54. There are areas of weak deformation in the large end and long arm sections of the forging, with a strain of only 0.20. The overall deformation of the forging during forming is also uneven, resulting in significant differences in performance between different parts of the forging. In this comparative example, the lower mold cavity in the weak deformation area is a recessed, arc-shaped boss, but the radius of the arc is smaller than that in the example, resulting in less compression of the billet and relatively weaker deformation.

[0117] Those skilled in the art will understand that the above discussion of any embodiment is merely exemplary in nature and is not intended to imply that the present application is limited to these examples; the above embodiments or technical features among different embodiments can also be combined, steps can be implemented in any order, and there are many other changes, such as the different aspects of one or more embodiments of the present application as described above, which are not provided in detail for the sake of brevity.

[0118] One or more embodiments of the present application are intended to cover all such alternatives, modifications, and variations as fall within the broad scope of the present application. Accordingly, any omission, modification, equivalent replacement, improvement, etc. made within the spirit and principle of one or more embodiments of the present application should be included in the scope of the present application.

Claims

1. A swage die for a curved Y-shaped aluminum alloy forging, characterized by, The curved Y-shaped aluminum alloy forging is in Y shape as a whole, comprising a head (105) and two arms (106), an upper surface (101) of the head (105) is provided with an A-shaped boss (102), upper surfaces of the arms (106) are provided with cylindrical bosses (103), and a lower surface of the curved Y-shaped aluminum alloy forging is in curved arc shape as a whole, with the turning point of the arc being located at the head; The die forging die comprises an upper die (3) and a lower die (4), and a cavity with a shape matched with the curved Y-shaped aluminum alloy forging is formed between the upper die (3) and the lower die (4); The upper die (3) is provided with cavities for forming the A-shaped boss (102) and the cylindrical boss (103); The lower die (4) corresponding to the turning point of the arc is provided with head process bosses (401), the head process bosses (401) are in arc shape, and the radius of the arc is not less than 15 mm; The lower die (4) corresponding to the position of the cylindrical boss (103) is provided with arm process bosses (402), the arm process bosses (402) are in arc shape; The number of the head process bosses (401) is three; The radius of the arc of the head process bosses (401) is 15-40 mm, and the radius of the arc of the three head process bosses (401) decreases successively from the head (105) to the arm (106).

2. The swage die of claim 1 wherein, The radius of the arc of the three head process bosses (401) is 30-40 mm, 20-22 mm and 15-18 mm respectively from the head (105) to the arm (106).

3. The swage die of claim 2 wherein, The central angles corresponding to the arcs of the three head process bosses (401) are 70-80°, 120-140° and 35-45° respectively.

4. The swage die of claim 1 wherein, The distance between the three head process bosses (401) is 4 mm, and the fillets between the three head process bosses (401) and between the head process bosses (401) and the lower die (4) are 4 mm.

5. The swage die of claim 1 or 2, wherein, The radius of the arc of the arm process boss (402) is 10 mm, and the fillet between the arm process boss (402) and the lower die (4) is 5 mm.

6. A method of forming a curved Y-shaped aluminum alloy forging, characterized by, The method comprises the following steps, forging the square billet into a Y-shaped billet through a blanking die; placing the Y-shaped billet in the die forging die according to any one of claims 1-5 and forging to obtain the curved Y-shaped aluminum alloy forging.

7. The forming method of claim 6 wherein, The weight ratio of the square billet to the Y-shaped billet is 1-1.1:

1.

8. The forming method of claim 6 wherein, The thickness ratio of the Y-shaped billet to the curved Y-shaped aluminum alloy forging is 1.1-1.4:1, and the length ratio of the Y-shaped billet to the curved Y-shaped aluminum alloy forging is 0.7-0.9:

1. ​

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