This paper describes the results obtained studying the feasibility of stamped automotive components by using aluminum alloys instead of standard steel. The advantage of using aluminum alloys consists of weight reduction of the components, decrease in forging forces and increase in die life. On the other hand, the use of aluminum implies a redesign of the production process. In fact, in order to keep the resistance of the component, the critical sections of the parts must be optimized and, in some particular cases, thermal treatrnents are required either locally or on the whole parL The feasibility study here presented has been conducted both by using F.E.M. simulations and experimental testing. The studied aluminum alloy 7075 T6, has shown a good attitude to be forged in a range of temperature between 380degC and 430degC. In particular, the use of the alloy into the temperature interval described, when forging the flange (simple geometry), has not shown any kind of problem. On the other hand, when the geometry of the forged piece becomes more cornplex (i.e., the anterior arm of the suspension) in order to assure the best material flow, a more precise working temperature is recommended (400degC). Moreover, during the optimization phase of the production processes some other working parameters have been taken into account and controlled. To be able to substitute a steel component with an aluminum one, means to perform additional thermal treatments and, in sorne cases, to re-design the component increasig the dimensions of the critical sections of the part. Finally, the suggestions obtained by using two and three dimensional FEM codes, can drastically reduce the lead times for the design of new production processes which results in low developrnent costs: FEM results are in good agreement with experimental evidence and consequently seem to be reliable in describing the actual cases.


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    Title :

    Innovation in the use of aluminum alloy for forming industrial automotive components


    Additional title:

    Innovationen beim Einsatz von Aluminiumlegierungen zur Herstellung industrieller Automobilteile


    Contributors:
    Ceretti, E. (author) / Giardini, C. (author) / Maccarini, G. (author)


    Publication date :

    2002


    Size :

    6 Seiten, 6 Bilder, 6 Quellen


    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English




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