November 2019 Volume 1

FORGING RESEARCH

Figure 6.4-9: Simulation results for AZ80 @ 300 o C at 8mm/sec. .....................................................................................................63 Figure 6.4-10: Simulation results for ZK60 at 300 o C at 8 mm/sec....................................................................................................63 Figure 6.4-11: Forging load at ram speed, AZ80 at 5 mm/s, ZK60 at 1 mm/s @ 300 o C....................................................................64 Figure 6.4-12: Load vs stroke graph for AZ80 @ 400 o C....................................................................................................................65 Figure 6.4-13: Forging trial result for ZK60 forged at 450 o C............................................................................................................66 Figure 6.4-14: Speed profile used to perform simulation to repeat the forging trial performed at CanmetMATERIALS..................67 Figure 6.4-15: Load vs displacement - simulation results vs forging trial for ZK60............................................................................67 Figure 6.4-16: ZK60 geometric comparison with simulation. Yellow is the model-predicted final forged geometry overlaid on the actual forging...............................................................................................................................................................................................68 Figure 6.4-17: Bending fixture at University of Waterloo...................................................................................................................70 Figure 6.4-18: Schematic of the bending process. ..............................................................................................................................71 Figure 6.4-19: Extruded AZ80 @ 400 oC Bending Process Simulation.............................................................................................71 Figure 6.4-20: Effective strain and damage distribution form bending simulation............................................................................72 Figure 6.4-21: Preform bending process at Multimatic Inc................................................................................................................73 Figure 6.4-22: Checking bend angle against the bend gauge.............................................................................................................73 Figure 6.4-23: Model-predicted AZ80 at 400 o C (a) Effective strain distribution of forged part with bent preformedmodelled in a CAD software (b) Effective strain distribution of the forged part with bent preform formed using a bending operation in DEFORM 3D.74 Figure 7.1-1: Model-predicted peak forging load, flow stress vs temperature......................................................................................6 Figure A-1: Flow curve for extruded AZ80 [49].................................................................................................................................85 Figure A-2: Flow curve for extruded ZK60 [50].................................................................................................................................85 Figure B-1: Multi-section cylindrical billet drawing [54]...................................................................................................................86 Figure B-2: Flat billet drawing...........................................................................................................................................................87 Figure B-3: Bent cylindrical billet drawing........................................................................................................................................88 Figure C-1: Simulation results for AZ80 @ 300 o C at 8mm/sec.........................................................................................................89 Figure C-2: Simulation results for ZK60 @ 300 o C at 8mm/sec.........................................................................................................90

List of Tables Table 3.2-1: Test matrix for the shear hat tests....................................................................................................................................18 Table 4.1-1: AZ80 at 300 o C at 1/s - ED and TD direction stresses....................................................................................................22 Table 4.1-2: Hill's coefficient AZ80 @ 300 o C@ 1/s..........................................................................................................................22 Table 4.2-1: Mesh sensitivity analysis – no. of elements vs load vs simulation time.............................................................................28 Table 4.3-1: Parametric studies simulation matrix.............................................................................................................................31

FIA MAGAZINE | NOVEMBER 2019 50