Numerical simulation of the forming process of RS/PM high damping aluminum alloy

The extrusion forming process of a rapidly solidified/powder metallurgy (RS/PM) damping aluminum alloy, FMS0714/10(Zn-30Al), is studied using the finite element software ANSYS. The effects of friction coefficient and extrusion ratio on the forming process are investigated in a wide parametric variation region, f, 0-0.2; λ, 2.78-8.65. Optimization of the forming process is performed to reduce the surface flaw of the material. Numerical results show that during the extrusion forming process the flow and deformation of the FMS0714/10(Zn-30Al) material are non-uniform, which results in the high stress and strain gradient. Stress and strain values near the surface are larger, while those near the center are smaller. Excessive surface strain and surface tensile stress, which are the main reasons for surface crack, can be reduced by enlarging the extrusion ratio and decreasing the friction between die and billet, thereby the material surface quality will be modified and the product qualification will be increased. The numerical simulation results can be treated as good references not only for constituting extrusion techniques of FMS0714/10(Zn-30Al) material, but also for designing and preparing new materials.