Research on local loading method for an aluminium-alloy hatch with cross ribs and thin webs

Complex-shaped rib–web parts are widely used in aviation and aerospace industry, but they are very difficult to manufacture by conventional forging method. Through studying deformation characteristic of whole loading by FEM simulation and experimental research in the process of forging 2014 aluminium-alloy hatch, which is a typical rib–web component, the causes of various forging defects have been analyzed. Based on the analysis of whole loading a local loading method is put forward, the forming process of rib–web hatch has been investigated and the rib–web part has been fabricated with good forming quality. The results indicate that local loading forming process is a reliable method to form the rib–web forging because local loading method can predict and control metal flow direction effectively, change metal flow from the long distance into short distance, which may eliminate various forming defects, such as overlap, breaking of rib and disturbance of forging flow line. Transitive die plate and bolster plate are helpful to realize local loading, which can control metal flow and improve forming quality. The reasonable design and utilization of transitive die plate and bolster plate are crucial to ensure the forming quality of rib–web parts.