Material driven workability simulation by FEM including 3D processing maps for magnesium alloy

The three-dimensional (3D) processing maps considering strain based on the two-dimensional (2D) processing maps proposed by PRASAD can describe the distribution of the efficiency of power dissipation and flow instability regions at various temperatures, strain rates and strains, which exhibit intrinsic workability related to material itself. Finite element (FE) simulation can obtain the distribution of strain, strain rate, temperature and die filling status, which indicates state-of-stress (SOS) workability decided by die shape and different processing conditions. On the basis of this, a new material driven analysis method for hot deformation was put forward by the combination of FE simulation with 3D processing maps, which can demonstrate material workability of the entire hot deformation process including SOS workability and intrinsic workability. The hot forging process for hard-to-work metal magnesium alloy was studied, and the 3D thermomechanical FE simulation including 3D processing maps of complex hot forging spur bevel gear was first conducted. The hot forging experiments were carried out. The results show that the new method is reasonable and suitable to determine the appropriate process parameters.