Metal Science and Heat Treatment

Vol. 48, Nos. 7 8, 2006

UDC 620.184./186:669.715:621.7.011

EXPERIENCE IN SIMULATION FOR PREDICTING THE STRUCTURE OF DIE FORGINGS

N. V. Biba,1 S. A. Stebunov,1 A. V. Ovchinnikov,2 and V. P. Shmelev3
Translated from Metallovedenie i Termicheskaya Obrabotka Metallov, No. 7, pp. 49 52, July, 2006.
Formation of structure and properties of an aluminum alloy is considered on an example of wheel forging with the use of the Zener Hollomon parameter. Parts of a forging most dangerous from the standpoint of coarsening of the structure are considered, namely, the web, the thread, and the upper and lower rims. A predicting technique is suggested and implemented for the case of die forging of a car wheel from aluminum alloy of grade AB in a split die.

INTRODUCTION Die forged car wheels from light and strong aluminum alloys are an obligatory attribute of todays automotive industry. One of the tasks solved by the industry consists in ensuring a high level of mechanical properties in articles of quantity production. A favorable combination of the degree of deformation of individual regions of a forging with appropriate temperature and rate modes of the deformation ensures a homogeneous structure in the metal and determines, together with the heat treatment, the finishing properties of the article. Prediction of the structural state will make it possible to evaluate the properties of the future article [1]. Recrystallization is a process most strongly affecting the structure of hot-deformed metal. Depending on the moment of occurrence of this process we distinguish dynamic recrystallization (occurs and develops in the process of deformation), static recrystallization (occurs and develops during heating of the deformed metal, for example, during heating for quenching), and metadynamic or spontaneous recrystallization (occurs right after the end of hot pressure treatment [2, 3]). In hot pressure deformation the stored energy and the resulting structural state except for the deformation degree depend on the temperature and the rate of the deformation. The author of [4] has used the Zener Hollomon parameter for plotting stress-strain diagrams for aluminum and aluminum alloys, which determine in the final analysis the structural state of semiproducts right after the end of each process step. However, for heat-hardenable alloys it is im1 2 3

portant to know not so much the structure in the freshly deformed state as the structure after heating to the hardening temperature that can be higher or lower than the initial temperature of recrystallization. Accordingly, the heat-treated semiproduct acquires either a cellular or a recrystallized structure. In this case the stress-strain diagram can be used as a diagram of structural state (Fig. 1) plotted in the rate of

t, C
500 11

A C I

B IV

450

12

400

13

III
14 15

C II

A
350

B
300

16 17 18 19 20

250 0.001

21 0.01 0.1 1 10

e, sec 1 Fig. 1. Diagram of structural states of aluminum alloy AB after & 50% deformation at different rates e and temperatures t followed by heating for hardening to 520C. The numbers at the curves present the values of log Z (Z is the Zener Hollomon parameter) [5]: ^) hub; )) web; O) rim; =, &) lower and upper rims, respectively; I ) recrystallization is absent; II ) complete recrystallization; III ) partial recrystallization; IV ) recrystallization in the deformation process.

100

NPO TsNIITMaSh Joint-Stock Company, Moscow, Russia. Stupino Department of the Tsiolkovsky Moscow Aircraft Engineering Institute, Stupino, Moscow Region, Russia. Stupino Metallurgical Company, Stupino, Moscow Region, Russia.

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deformation temperature of deformation coordinates for alloy AB in [5]. Line AA on the diagram separates the range of hot deformation I after a treatment in which recrystallization does not occur in heating for hardening. This line characterizes the interdependence of two critical parameters of hot deformation. i.e., the rate and the temperature of the deformation, and is known as the line of critical states [5]. In the metal deformed above line AA the level of stored energy is insufficient for the occurrence of recrystallization in heating for hardening. Line BB is the temperature and rate boundary of region II where the stored energy ensures complete recrystallization. Region III of partial recrystallization lies between lines AA and BB. The structure of the metal deformed in this region and heated for hardening is mixed. Region III is the most dangerous from the standpoint of nonuniform coarsening of the structure and, consequently, from the standpoint of degradation of mechanical properties. The largest grains form in the middle of the region of partial recrystallization where they grow relatively freely. Due to the quite long size of this region (log Z = 13 15) the critical values of log Z that correspond to the beginning of coarsening of the structure require amending. The task of the present work was to develop a method for using the data obtained with the help of the QForm software in the form of temperature fields and degrees and rates of deformation for predicting the structural state of the metallic material of a preform. METHODS OF STUDY Computer simulation of the process of die forging was performed with the help of a domestic QForm system based on a finite-difference model of plastic deformation. The geometry of the tools and preforms was processed by the AutoCAD graphic editor and imported into the internal format of the QForm system through the DXF standard. When simulating the processes of upsetting and forging we used the following initial data and boundary conditions in the QForm system on the basis of clocking of actual processes and using process recommendations: a data base on the resistance of alloy AB to deformation; the temperature of heating the preforms for deformation equal to 460C; the time of transfer of the preform from the furnace to the tool equal to 11 sec; the time of cooling of the preform in the tool before the beginning of the deformation equal to 11 sec; suspension of graphite in mineral oil as the process lubricant; the temperature of the tool equal to 330C. The preforms for upsetting were obtained from cut-tolength segments of cast bars from alloy AB turned to a dia-

meter of 230 mm. The chemical composition of the metal in the heat met the requirements of the GOST 478484 Standard. The macrosections were prepared by methods standard for aluminum alloys. The tests for upsetting of cylindrical test pieces were performed in an FP100 mechanical testing machine developing a power of 100 kN under isothermal conditions; the temperature was kept accurate to 1C. The method for predicting the structural state of materials was tested for the process of die forging of a car wheel disk from aluminum alloy AB in a split die on a hydraulic press. The method is implemented in several stages. At first, the process of die forging is simulated in the QForm system [1] and the obtained distribution of the degree, temperature, and rate of the deformation over the volume of the forging is analyzed. Then a quantity proportional to the level of the stored energy is computed and the critical zones in the forging are determined. In the final stage the corrected modes of die forging are checked by simulation and ways for avoiding supercritical values of stored energy are determined. The stored energy is measured in terms of the Zener Hollomon parameter Z, which is a criterion of the joint effect of the temperature T, the degree e, and the rate & e of deformation on the strain resistance and, indirectly, on the forming structure [3], i.e., Q Z = & exp e , RT where Q is the activation energy of plastic deformation and R is the gas constant. RESULTS AND DISCUSSION We studied the macrostructure (see Fig. 2) of specimens of alloy AB deformed under temperature and rate conditions of region III and hardened from 520C and established that the value log Z = 14 (deformation rate & = 0.05 0.12 sec 1, e deformation temperature tdef = 420C) was critical for the recrystallization process to occur during heating for hardening. As the deformation temperature decreased from 430C the first regions with recrystallized grains appeared at tdef ~ 415C (Fig. 2a and b ). Further decrease in the temperature caused growth in the volume fraction of recrystallized grains. They were located within a specific cross-shaped region in the axial section of the preform after upsetting (Fig. 2c ). Most processes of die forging of complex preforms are conducted with many steps (see Fig. 3). Theoretically, each step contributes into the level of energy stored in the structure of the metal. In practice, the temperature and rate modes of deformation are affected considerably by cooling of the preform due to the contact with the atmosphere and with the less heated die. For this reason the forming operation finishes at a substantially higher value of log Z than it has begun, and

Experience in Simulation for Predicting the Structure of Die Forgings

325

Fig. 2. Microstructure of alloy AB after upsetting at a rate of 1.5 mm/sec and water hardening at 520C for 1 h. The deformation temperature is: a) 430C; b ) 415C; c) 407C.

Fig. 3. Changes in the shape of a preform in different stages of double-impression forging of a car wheel disk in a split die: a) initial preform (forging); b ) after upsetting; c, d ) after preliminary and final die forging respectively.

Fig. 4. Distribution of the deformation temperature (a) and rate (b ) over the cross section of a disk forging in the final stage of the forging process. Simulation in the QForm system.

this makes it possible to use the final stage of die forging for analyzing the conditions of structure formation. We obtained the initial data for such analysis (the temperature and rate fields in the course of the deformation) by simulating the process of die forging in the QForm system with the use of traced points (see Fig. 4). We studied the components of the forging most dangerous from the standpoint of coarsening of the structure, namely, the web, the thread, and the upper and lower rims (Fig. 5). Superposition of the results of the simulation on the

diagram of structural states of alloy AB (Fig. 1) after deformation and hardening shows that all components of the forging lie in region III most dangerous from the standpoint of coarsening of the structure. However, taking into account the amended critical value of log Z = 14 we can say that only the lower and upper rims and some parts of the web and of the thread get into the range of supercritical values of the Zener Hollomon parameter (points 42, 28, 38, and 48 in Fig. 5). This is explainable by the fact that in this stage of final forging the flow of metal is the most intense into the

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Upper rim 27 39 34 Web Thread 28 46

54 32 48

47 36 Lower rim

35

42

38

Fig. 5. Location of traced points (numbered at the curves) over parts of a forging within the contour of the preform.

lower rim, the web and the bend of the thread deform actively (point 48 in Fig. 5), and the upper rim acquires the final form. In order to determine the causes of the elevated level of stored energy in these parts of the forging and to determine the ways for avoiding this situation we resorted to a joint analysis of the temperature and rate conditions of the deformation and of the dynamics of variation of the quantity log Z. The volume of the web marked by points 28 and 38 (Fig. 5) displaces intensely to the cavity of the lower rim in the course of closure of the dies. In the first turn, this is reflected by the principal difference in the rate modes of the deformation (Fig. 6a ). Starting with the seventh second of the forging process the rate of the deformation increases abruptly to 0.7 1.0 sec 1, which is responsible for the supercritical finishing values of log Z = 14.2 14.6. The metal starts to flow into the lower rim simultaneously with the beginning of intense compression of the web. However, in addition to some cooling of the metal (to at least 440C) its deformation is characterized by a noticeably higher rate, especially in the final stage of the finishing forging. In the
tdef , C
455 450 445 440

course of the process the regions around points 36, 47, and 46 are successively extruded into the cavity of the lower rim that has a shape of a narrowing channel with bends. Point 36 has enough time for passing the whole way, and the maxima and minima on the dependence for the deformation rate (Fig. 6b ) agree well with the number and succession of the channel bends. Despite the determined dependence of the quantity log Z on the temperature and rate parameters of the deformation it is impossible to make an unambiguous conclusion on priority of the effect of the temperature or of the rate on the value log Z and, accordingly, on the level of the stored energy. The problem of supercritical values of log Z can be solved by controlling the temperature or the rate of the deformation. It is impossible to eliminate the cooling without additional costs. Theoretically, the problem is solvable by the use of isothermal forging, but in a mass production of competitive articles from aluminum alloys this is hardly expedient. The speed of motion of the traverse of a hydraulic press is determined by the ratio of the required forging force to the maximum force developed by the press. In its turn, the resistance of the material of the preform to deformation depends substantially on the rate of the deformation and decreases with decrease in the latter. This makes it possible to control the rate of the deformation of the material of the preform by limiting the forging force to a specified value by controlling the throttle of the press. This technique is known as creep forging [6] and is used for isothermal forging of articles from hard-to-deform metals and alloys in order to ease the operating conditions of the tool. Analysis of results of computer simulation of such operating mode in the QForm system shows that at the same filling of the impression the rate mode of the deformation is more favorable. As a result, the maximum levels of log Z acting in the end of the process of final forging in the web and in the lower rim (Fig. 7) do not exceed the critical value of 14. It is especially important that the forging process ends at log Z < 14.
e, sec 1
2.0

. e, sec 1 tdef , C
1.0 0.9 0.8 455 450 445 440 435 430 425 420 4 5 6 7

tdef

1.8 1.6 1.4 1.2

log Z
15.0 14.5 14.0 13.5 13.0 12.5

tdef log Z = 14.0

0.7 0.6 0.5 0.4

log Z = 14.0

1.0 0.8

435 430 425 420 3.5

log Z e
4.5 5.5 6.5

0.3 0.2

log Z e

0.6 0.4

t, sec
7.5

0.1 0

b
8

0.2 0

t, sec

Fig. 6. Variation of the temperature, of the deformation rate, and of log Z in the process of forging for a region of the web at point 38 (a) and for the lower rim at point 36 (b ).

Experience in Simulation for Predicting the Structure of Die Forgings

log Z
15.0 14.5 14.0 13.5 13.0

327
log Z
15.0 14.5

log Z = 14

14.0 13.5 13.0 12.5

log Z = 14

Fig. 7. Variation of the quantity log Z in the process of final forging in presses developing a force of 100 MN (O) and 67 MN (=) at point 38 of the web (a) and at point 36 (b ) of the lower rim.

12.5

12.0 4 5 6 7 8

b
9 12.0 4 5 6 7 8

t, sec

t, sec

CONCLUSIONS 1. Computation of the process of die forging in the QForm system gives enough information on the temperature and rate conditions of the deformation at any point of the preform for controlling the structural state of the forging. 2. The experimentally plotted diagram of structural state of alloy AB is adequate to the simulated temperature and rate conditions of the deformation. 3. Simultaneous analysis of the diagram of structural states and of the temperature and rate fields in a plastically deformed body obtained as a result of simulation has made it possible to develop a method for predicting and controlling the structural state of the material in a deformed semiproduct.

REFERENCES
1. N. V. Biba and S. A. Stebunov, Q-Form software created for technologists, Kuzn.-Shtamp. Proizv., No. 9, 38 42 (2004). 2. Yu. M. Vainblat, Diagrams of structural states and maps of structures of aluminum alloys, Metally, No. 2, 82 (1982). 3. Z. N. Archakova, G. A. Balakhonstev, I. G. Basova, et al., Structure and Properties of Semiproducts from Aluminum Alloys, A Handbook [in Russian], Metallurgiya, Moscow (1984). 4. Yu. M. Vainblat, Structural states of semiproducts from deformable aluminum alloys, Tekhnol. Legk. Splavov, No. 8, 34 (1992). 5. I. I. Novikov, The Theory of Heat Treatment of Metals [in Russian], Metallurgiya, Moscow (1978). 6. Forg. and Prop. Aerospace Materials, Proc. Int. Conf. Leeds, London (1978).