November 2019 Volume 1

FORGING RESEARCH

Table of Contents Author’s Declaration .........................................................................................................................................................................ii Abstract ............................................................................................................................................................................................iii Acknowledgements ...........................................................................................................................................................................v Table of Contents ..............................................................................................................................................................................vi List of Figures ...................................................................................................................................................................................viii List of Tables......................................................................................................................................................................................xi Chapter 1 Introduction......................................................................................................................................................................1 1.1 Motivation...................................................................................................................................................................................1 1.2 APC Project Overview.................................................................................................................................................................2 1.3 Objectives:...................................................................................................................................................................................2 Chapter 2 Literature Review..............................................................................................................................................................3 2.1 Deformation Mechanisms During Forging.................................................................................................................................3 Yield Function – Hill’s Coefficient.....................................................................................................................................................5 Forging Process Design &Modelling of Hot Deformation of Magnesium........................................................................................8 extruded starting material. Shear hat tests were performed at strain rates of 0.1/s and 1/s at multiple temperatures for AZ80 &ZK60 alloys. After the simulation was complete and verified, multiple parametric and sensitivity studies were performed to determine the effect of factors such as flash land, friction, temperature and ram speed on the predicted forging load and material flow. It was determined that increasing the flash width will increase the press load while decreasing it too much will result in under-fill in the die cavity. It was determined that a flash width of 5 mm created a good balance to achieve a complete die fill while minimizing the forging load for this application. Friction plays a similar role as flash land: increasing it increases the load while reducing it too much results in under-fill. A friction factor of 0.2 was used based on testing with the friction modifier used in subsequent testing. Multiple preform shapes were examined to ensure the final geometry for the control arm could be achieved in one forging step using the CanmetMATERIALS 1500 tonne press. The preform shapes studied included a multi-section cylindrical, flat plate and bend cylindrical billet. The bent cylindrical billet was selected as it met all the project requirements. Acknowledgements Firstly, I would like to offer my sincere gratitude to my supervisors Prof. Mary Wells and Prof. Steve Lambert for their outstanding support, expertise and understanding.They providedme not only with the technical guidance and support but also themoral support andmotivation. Without them my thesis would not have been possible. I would also like to thank Tharindu Kodippili for his support and help during my research work. I would like to also offer my special thanks to Bruce Williams and Jonathan McKinley of CanmetMATERIALS laboratory in Hamilton, Ontario for the valuable suggestion and detailed discussions. I am also grateful for the guidance, support and insight provided by Alex Duquette, Jim Prsa, Tom Sparrow and Andy Georgiou of Multimatic Inc. The detailed discussions raised many critical question and hopefully I answered most of them in this thesis. I am very thankful for the help and support provided by the research group at University of Waterloo. I would like to specially thank Andrew Gryguc, Paresh Prakash, Massimo DiCiano, Rick Wong, Amir Hadadzadeh, and last but not least Behzad Behravesh for the detailed discussions and deep insight on my thesis. I would like to extend my sincere appreciation to my colleague and friends Waqas Muhammed and Dr. Usman Ali for their support, motivation and advice. Also would like to acknowledge Automotive Partnership Canada for providing the financial support for the project. Finally, I would like to extend my profound gratitude to my family. I would also like to offer my thanks to my brother for his support and sacrifices. I would also like recognize my parents for their prayers and blessings, without which this document would not be possible.

FIA MAGAZINE | NOVEMBER 2019 47