Abstract
An approximate similarity theory has been applied to predict the forming load of non-axisymmetric forging of aluminum alloys through model material tests. The approximate similarity theory is applicable when strain rate sensitivity, geometrical size, and die velocity of model materials are different from those of real materials. Actually, the forming load of yoke, which is an automobile part made of aluminum alloys(Al-6061), is predicted by using this approximate similarity theory. Firstly, upset forging tests are have been carried out to determine the flow curves of three model materials and aluminum alloy(Al-6061), and a suitable model material is selected for model material test of Al-6061. And then hot forging tests of aluminum yokes have been performed to verify the forming load predicted from the model material, which has been selected from above upset forging tests. The forming loads of aluminum yoke forging predicted by this approximate similarity theory are in good agreement with the experimental results of Al-6061 and the results of finite element analysis using DEFORM-3D.
