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Numerical simulation of billet height-diameter ratio on magnesium alloy automobile wheel formed by back extrusion

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Abstract

Magnesium (Mg) alloy wheels are widely concerned for their satisfactory energy saving and emission reduction effects and increased driving comfort. However, the current single-step back extrusion (BE) forming process of Mg alloy wheels uses a relatively small billet height-diameter ratio (HDR), which results in coarse grains and uneven grain size distribution of the spokes, seriously affecting the service performance of the wheel. A numerical model of the Mg alloy wheel was constructed based on the actual single-step BE process of the Mg alloy wheel in this study, and the effect of billet HDR on the physical field and dynamic recrystallization (DRX) grain size during the forming process of Mg alloy wheel was explored through numerical simulation. Finding reveals that as the HDR of the billet increases, the overall effective strain of the wheel increases, the overall DRX volume fraction increases, and the grains are refined. When the HDR of the billet is greater than 1, the overall grain size distribution of the wheel tends to be stable. Compared with the traditional small HDR, when the billet HDR is greater than 1, the grain size at the spokes is reduced from the original 60 ~ 120 to 30 μm. During the forming process of the wheel, the upper rim is prone to cracking. With the increase of the HDR of the billet, the damage value at the upper rim of the wheel increases, i.e., the cracking tendency at the upper rim increases. Simultaneously, the cracking tendency of the outer side of the rim increases with the HDR of the billet. Considering it comprehensively within the scope of this study, it is recommended to set the HDR of the wheel billet between 0.7 and 1.

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Funding

This work was supported by the National Natural Science Foundation of China (Grant No. 51974082); the Fundamental Research Funds for the Central Universities (Grant number: N2202018); and the Programme of Introducing Talents of Discipline Innovation to Universities 2.0 (the 111 Project 2.0 of China, No. BP0719037).

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Authors and Affiliations

  1. Key Lab of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang, 110819, People’s Republic of China

    Yanchao Jiang, Liang Ren, Qichi Le, Yatong Zhu, Weiyang Zhou & Tao Zhao

  2. School of Materials Science and Engineering, Northeastern University, Shenyang, 110819, People’s Republic of China

    Qiyu Liao

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  1. Yanchao Jiang
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  2. Liang Ren
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Contributions

Simulation calculation, data collection, and analysis were performed by Yanchao Jiang, Liang Ren, Qichi Le, Qiyu Liao, and Yatong Zhu. The first draft of the manuscript was written by Yanchao Jiang, and all the authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Yanchao Jiang or Qichi Le.

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Jiang, Y., Ren, L., Le, Q. et al. Numerical simulation of billet height-diameter ratio on magnesium alloy automobile wheel formed by back extrusion. Int J Adv Manuf Technol 125, 529–542 (2023). https://doi.org/10.1007/s00170-022-10732-z

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