Numerical Modeling of the Forging Response of a Magnesium Alloy Control Arm

The pronounced temperature and strain-rate sensitivity of magnesium alloys were apparent during full-scale forging of control arm components. To achieve the required fatigue resistance of ZK60 and AZ80 control arms, it was necessary to forge at a low temperature of 300 °C. At this temperature, a slow strain rate was used to ensure the force required for forging was within the available load capacity of the equipment. The final forging sequence required to achieve complete material fill of the component was determined through a combination of experimental forging and numerical simulations. The temperature and rate sensitivity of the alloys and the material model utilized in the simulations will be detailed. Differences between Adaptive Remeshing (AR), Arbitrary Lagrangian–Eulerian (ALE), and Combined Eulerian–Lagrangian (CEL) finite element methods for predicting large deformation under isothermal conditions will be discussed. The challenges of forging a complex-shaped magnesium alloy component are highlighted.