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<p>Aircraft wheel hubs typically have a thin-walled and deep-cavity structure, which often results in folding defects in the flange region during the forming process. In this study, the DEFORM software was used to investigate the reasons for folding defects and proposed optimization strategies. The results indicate that increased workpiece thickness (volume) and uneven lubrication distribution within the die are the primary factors for folding defects. Specifically, the increase in workpiece thickness (volume) elevates the height-to-width ratio (h/b) of the flange region, and the uneven distribution of lubrication contributes to the circumferential flow of the metal and generates a transverse stress, both of which collectively result in folding defects. Subsequently, a U-shaped initial pre-forging approach was proposed to limit flange formation to the top die, thus mitigating the effects of unstable workpiece thickness (volume) and uneven die lubrication on the forming quality. The optimized scheme was successfully implemented in trial production, validating its effectiveness, providing a crucial reference for manufacturing similar high-performance forgings in aerospace and other critical industries.</p>

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Analysis and optimization of folding defects in aircraft aluminum alloy wheel hubs

  • 期刊论文

  • 发表日期：

    2025年2月25日

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  • Shishan Li,
  • Jie Zhou,
  • Jiawen Li,
  • Yi Qin,
  • Shuai Long,
  • Daoxiang Wu,
  • Heping Deng,
  • Fanjiao Gong-ye,
  • Yuting Zhou

摘要

Aircraft wheel hubs typically have a thin-walled and deep-cavity structure, which often results in folding defects in the flange region during the forming process. In this study, the DEFORM software was used to investigate the reasons for folding defects and proposed optimization strategies. The results indicate that increased workpiece thickness (volume) and uneven lubrication distribution within the die are the primary factors for folding defects. Specifically, the increase in workpiece thickness (volume) elevates the height-to-width ratio (h/b) of the flange region, and the uneven distribution of lubrication contributes to the circumferential flow of the metal and generates a transverse stress, both of which collectively result in folding defects. Subsequently, a U-shaped initial pre-forging approach was proposed to limit flange formation to the top die, thus mitigating the effects of unstable workpiece thickness (volume) and uneven die lubrication on the forming quality. The optimized scheme was successfully implemented in trial production, validating its effectiveness, providing a crucial reference for manufacturing similar high-performance forgings in aerospace and other critical industries.