A large number of new forging processes and technologies have been developed in the technical direction of aluminum and aluminum alloy forgings, such as liquid die forging, semi-solid die forging, isothermal forging, powder forging, multi-directional forging, non-slope precision die forging, partial die forging, cladding die forging, etc., which are beneficial to simplifying the process, reducing working procedures, saving energy consumption, expanding quality, increasing specifications, improving quality and consumption efficiency, maintaining the environment, reducing labor intensity and improving economic benefits. Lanxi Tongli Aluminum Co., Ltd. said that the special computer software provided a reliable guarantee for controlling the main process parameters such as forging temperature, forging pressure, deformation degree (under-pressure) and process lubrication, and controlling the product size, internal structure and mechanical properties.

The design and manufacture of die forging is the key of aluminum alloy forging technology. The forging CAD/CAM/CAE system has been very mature and advanced. In the United States, the CAD/CAM/CAE system is being replaced by CIM (Computer Integration). CIM includes complete technology, computer technology, CAD/CAM/CAE technology, robot, expert system, machining plan, control system and automatic material disposal, which provides conditions for the optimal design and process improvement of die forgings. Lanxi Tongli Aluminum Co., Ltd. said that in the automobile industry, if the design and process optimization of the front beam, horn, hub and crankshaft are suspended, the optimized horn will lose weight by 15%, the hub will lose weight by 30% and the crankshaft will lose weight by 20%, and the consumption efficiency will be greatly improved and the energy consumption will be reduced.

Why is aluminum alloy forging irreplaceable?

Cars and some transmission shafts should be forged, mainly crankshaft parts. Forging is a processing method to stop hitting and shape massive and rod-shaped aluminum materials. The forging that stops when the forging blank is heated above the recrystallization temperature is called hot forging. Hot forging makes the forging blank close to the shape of the product, and changes the mechanical properties of aluminum forgings. Lanxi Tongli Aluminum Co., Ltd. indicated that the crankshafts, camshafts, sprocket gears, etc. which require high rigidity in automobile parts are all hot forging forgings. Automobile crankshaft is a kind of shaft component in automobile starter, which transforms the linear motion of driving piston into rotation. Crankshaft is composed of main shaft, piston connecting rod, connecting rod pin, balance weight and other parts fixed on the starter.

In the past, the materials used for automobile forging crankshafts were usually carbon aluminum and Cr-Mo aluminum for heat treatment (quenching and tempering). After 1970s, in order to reduce the data cost, the development of non-quenched and tempered aluminum was promoted. Nowadays, non-quenched and tempered aluminum such as V-containing carbon aluminum (high fatigue strength aluminum) and V-free carbon aluminum has become the mainstream aluminum for automobile forging crankshaft.

Lanxi Tongli Aluminum Co., Ltd. said that in addition, in order to change the fatigue strength of the crankshaft, after the crankshaft is machined, the high-frequency quenching, soft nitriding and rolling processing are stopped for the risk parts of the crankshaft, so as to change the strength of these parts.

When the automobile crankshaft is stopped forging, the forging blank is usually heated to about 1200℃ and then the hot forging is stopped. In this way, small forging equipment can be applied, small load can be applied, and good precision forging can be stopped. When manufacturing forged crankshafts, not only the quality control of forging should be stopped, but also the strict quality control should be stopped from crankshaft data design, crankshaft shape design, aluminum smelting to forging. Crankshaft or axle products processed by bar are easy to show quality objection of forging and cracking.

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