Study on Forging of SSA Component Rear Top Mount Housing

• Main Authors: Ching-Shun Lin, 林清順
• Other Authors: 陳立緯
• Format: Others
• Language: zh-TW
• Published: 2016
• Online Access: http://ndltd.ncl.edu.tw/handle/5428y3

碩士 === 國立虎尾科技大學 === 機械與電腦輔助工程系碩士班在職專班 === 104 === Overuse of fossil energy has resulted in global warming, and the major cause is the CO2 exhausted by motor vehicles, so that Kyoto protocol has set the target of 8% reduction of CO2 during 2008 to 2012. Since then, car manufacturers has presented many improvements, and one of the most effective methods for lightweight and energy saving is to produce parts by forging, thus higher mechanical properties and lighter weight of the metallic alloy parts can be reached. In this thesis, the compound forging of SSA part (Suspension System Architecture) rear top mount housing by using aluminums alloy AL6082 was studied. Firstly, thermal compression test on AL6082 was conducted by using GLEEBLE 3500 machine in ITRI, in which 4 different temperatures and 5 different strain rates were inter-tested. The true stress-strain curve was then obtained and input in DEFORM to conduct forming analysis, in which the metal forming condition, forging load, coefficient of friction between tooling and material, and heat transfer between part and tooling were studied. The results were provided to improve the tooling design and reduce the lead time and cost of tooling manufacture. The geometry of rear top mount housing in this study is very complex and cannot be forged by using conventional forging (uni-directional), so that three-way forging was introduced, in which the conventional top die and bottom die were used in mechanical press, and two additional lateral cylinders were added in the pressing. Thus, the shape of forged part was closer to the final product, so that the material yield rate was increased, machining cycle time was reduced, and higher mechanical properties were reached. The analysis results showed the processing parameters for conventional forging were: material temperature 540°C, die temperature 200°C, and frictional coefficient 0.3; In contrast, the processing parameters for three-way forging are: material temperature 450°C, die temperature 250°C, and frictional coefficient 0.3. Some experiments were conducted by using the parameters mentioned above, and the results showed both the conventional and three-way forging can reach the expected formability and mechanical properties.