Andrzej Gontarz, Krzysztof Drozdowski, Anna Dziubinska and Grzegorz Winiarski
The aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press.
Abstract
Purpose
The aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press.
Design/methodology/approach
The proposed forging technique has been developed based on the results of a numerical and experimental research. The required forging temperature has been determined by upsetting cylindrical specimens on a screw press to examine both plasticity of the alloy and the quality of its microstructure. The next stage involved performing numerical simulations of the designed forging processes for producing forgings of a door handle and a bracket, both made of magnesium alloy AZ61A. The finite element method based on simulation programme, Deform 3D has been used for numerical modelling. The numerical results revealed that the forgings are free from material overheating and shape defects. In addition to this, the results have also helped determine the regions that are the most prone to cracking. The final stage of the research involved performing forging tests on a screw press under industrial conditions. The forgings of door handles and brackets were made, and then these were tested for their mechanical and structural properties. The results served as a basis for assessing both the viability of the designed technique and the quality of the produced parts.
Findings
The experimental results demonstrate that aircraft components made of magnesium alloy AZ61A can be produced by die forging on screw presses. The results have been used to determine the fundamental parameters of the process such as the optimum forging temperature, the method of tool heating, the way of cooling parts after the forging process, and the method of thermal treatment. The results of the mechanical and structural tests confirm that the products meet the required quality standards.
Practical implications
The developed forging technique for alloy AZ61A has been implemented by the forging plant ZOP Co. Ltd in Swidnik (Poland), which specializes in the manufacturing of aircraft components made of non-ferrous metal alloys.
Originality/value
Currently, the global tendency is to forge magnesium alloys (including alloy AZ61A) on free hydraulic presses using expensive die-heating systems. For this reason, the production efficiency of such forging processes is low, while the manufacturing costs are high. The proposed forging technique for alloy AZ61A is an innovative method for producing forgings using relatively fast and efficient machines (screw presses). The proposed forging method can be implemented by forging plants equipped with standard stocks of tools, which increases the range of potential manufacturers of magnesium alloy products. In addition, this technology is highly efficient and ensures reduced manufacturing costs.
Details
Keywords
Krzysztof Drozdowski, Arkadiusz Tofil, Andrzej Gontarz, Zbigniew Pater and Janusz Tomczak
– The purpose of research was to work out manufacturing technology of plane rim from 2618A aluminium alloy based on hammer forging process.
Abstract
Purpose
The purpose of research was to work out manufacturing technology of plane rim from 2618A aluminium alloy based on hammer forging process.
Design/methodology/approach
It was assumed that the manufacturing process consists of die hammer forging and machining. The first stage of the research works was based on designing of the forging process and on numerical simulations in which finite element method was used. On the basis of calculations results, analysis of deformation parameters in the drop forging was made and the rightness of the worked out technology was verified. The second stage of the research works concerned experiments conducted in industrial conditions. Forging dies were constructed and the forging process of a series of drop forgings was carried out. Next machining was done to obtain finished parts.
Findings
The conducted research works on the forging process on hammer of the rim drop forging from 2618A aluminium alloy showed that the application of this technology allows for obtaining the product of good quality. Manufactured rims were destined for exploitative research works, aiming at getting certificate that would allow for their implementation in planes.
Practical implications
The rim is being prepared for implementation in small planes of considerably large wheels load.
Originality/value
The presented hammer forging method of plane rim has not been used so far. In the case of applying the rims in planes building, not only industrial plants with large forging presses but also forgeries with die hammers will be able to produce these parts.