Abstract:
In order to study the precision forming process of 6063 aluminum alloy contact seat, Gleeble-1500D thermal simulation test machine was first used to conduct high-temperature compression experiments on 6063 aluminum alloy, and the rheological stress curves under different deformation conditions were obtained. The flow stress increases with the increase of strain rate and decreases with the increase of deformation temperature, indicating that the alloy has sensitivity to normal strain rate. The experimental data was processed and its Arrhenius constitutive equation was obtained through linear fitting, where the activation energy for thermal deformation is 235.1548 kJ·mol
-1. Using experimental data to numerically simulate and analyze its compression thermal deformation process, the critical damage values under different strains were obtained, and the critical damage values are positively correlated with the strain rate. Then, numerical simulation software was used to analyze the precision forming process of a certain type of 6063 aluminum alloy contact seat. Orthogonal experiments were conducted to optimize the key process parameters that affect the forming quality. The optimized process parameter combination for precision forming of 6063 aluminum alloy contact seat was obtained as follows: forming temperature of 490 ℃, forming speed of 20 mm/s, and friction coefficient of 0.3. The equivalent stress distribution of the workpiece and the stress distribution of the mold during the forming process were analyzed. The mold stress is within the allowable stress range of H13 hot work mold steel and can not cause damage to the mold. Finally, corresponding process experiments were conducted to verify that the 6063 aluminum alloy contact seat forging obtained from the experiment is fully filled, and there are no forging defects after subsequent mechanical processing. This indicates that the precision forming process of the 6063 aluminum alloy contact seat developed in this research is feasible and has certain guiding value for the actual production of such parts.