Effective forming processes of hub forging from aluminum alloy AlCu2SiMn

This paper investigates the potential benefits, particularly with respect to material saving, of two new forging processes when compared to the more traditional method of hammer forging for the production of hubs. The processes can be realized by utilizing a press with three movable working tools. The first process is based on forming without flash of a forging with axial cavity. The second one is connected with forming of forging from pipe billet. Theoretical research involved simulations by means of finite element method. Simulations were mainly to determine kinematics of material flow in forging processes and the precision of shape and dimensions of products obtained. The first of the proposed processes was experimentally verified and a product of good quality was obtained. Material consumption of the analyzed processes and other factors related to their effectiveness were also compared.