高强韧铝合金轮毂的轻量化铸旋新工艺

综述了铸造铝合金的强韧化研究现状和最新进展,介绍了铝合金轮毂的铸旋成形新技术,分析了铸旋工艺在铝合金轮毂轻量化中的作用。分析表明热塑性形变韧化可成为A356合金强韧化的新途径,以此为基础发展的铸旋成形工艺可满足汽车轮毂进一步轻量化的要求。采用铸旋工艺成形的铝合金车轮轮辋部位的各项性能指标比低压铸造车轮有大幅提高,轮辋壁厚也可大幅度减薄,相同规格的车轮,采用铸旋工艺生产可减重5%～15%,实现了产品的高强度、轻量化要求,具有更轻的竞争力。之后重点介绍了铝合金轮毂铸坯热旋压工艺原理、A356合金的可旋性、工艺参数的选择及有限元分析在热旋压工艺设计中的应用,并指出存在的问题和所需做的进一步研究。结果表明铸造A356合金的热旋压可加工窗口较窄,成形温度控制是关键,为了促进铝合金轮毂铸旋工艺的广泛应用与发展,在铸造铝合金的热旋压变形性能、热旋压时金属的变形机理和流动行为,以及热旋工艺数值模拟和参数优化等方面还需要做大量的、深入系统的研究工作。

A New Cast Spinning Process for Light Weight Aluminum Alloy Wheels

The present research and recent progress on strengthening and toughening of cast aluminum alloys was reviewed,the cast spinning process of aluminum alloy wheels was introduced and the role of such processes on wheel weight saving was analyzed.The analyzed results showed that hot deformation could be a new strengthening and toughening method and the cast plus hot spinning process developed based on this could fulfill the light weight demand of aluminum wheels.Compared to wheels processed by the low pressure die casting,wheels produced by cast plus hot spinning process had higher mechanical properties and significantly reduced wall thickness at the rim.Then,a detailed information was introduced on principle of hot spinning process of cast aluminum alloy wheel perform,the hot spinnability of A356 alloy,selection of process parameters and application of FEM simulation on hot spinning process.And finally the existing problems and further research necessities were pointed out.The results showed that the key forming parameter was temperature control for hot spinning of cast A356 alloy,for the further development and application of cast plus hot spinning process,detailed research still needed on hot spinnability of cast aluminum alloys,deformation mechanism and metal flow rule during hot spinning process and numerical simulation and process optimization.