Shear Forging for Aluminum and Copper Materials

The features of shear forging for a pure aluminum A1100, aluminum alloy A5052 and pure copper C1100 were investigated using the simulations and experiments. Shear forging is a process of cold forging to form a H-shaped double cup from a bottomed cup using the material flow in cutting. One of the critical defects of shear forging is folding defect. The critical conditions of folding generation for each material are investigated using the simulations based on finite element method changing the ratio of the depth of cut to the bottom thickness of the cup and the corner radius of the counter punch. The shear forging experiments are conducted using a servo press. Products of all materials are formed without folding defects using the successful condition in the simulations. The surface textures of the forged products were measured by a scanning electron microscope and a grooved texture by cutting was observed. In addition the surface rubbed with the punch corner have small surface roughness.