Modelling studies on effects of deformation speed, preform shape, and upset ratio on the forging characteristics of the aerospace structural Al alloys

The purpose of the present work is to investigate the effects of deformation speed, preform shape, and upset ratio on the forging characteristics of aerospace structural Al alloys using finite element simulations. Three different aerospace grades of Al alloys (AA2014, AA2024, AA2618) and three preform shapes (cylinder, hexagonal prism, and cube), two upset ratios (2 and 4), and two deformation speeds (33.3 mm/s and 1 m/s) were selected in the study. Additionally, the data were statistically analysed using the analysis of variance technique to identify the significant parameters deciding the forging load requirements. The stress, strain, damage and temperature distributions for the various combinations of inputs were discussed in detail. The upset ratio is identified as the most significant parameter in deciding the forging load, followed by the deformation speed, the alloy type and the preform shape respectively.