Numerical Analysis of Residual Stresses in Quenched High-Strength Aluminum Alloy Ultra-Thick Plates and their Reduction through Single-Side Cold Compression Method

Abstract

Residual stresses developed after quenching of high-strength aluminum alloy ultra-thick plates have an important effect on the quality and reliability of parts, and should be reduction to meet the requirement. In this investigation, numerical techniques of SIMUFACT software are used to simulate residual stresses in quenched 340mm×127mm×124mm Al-Zn-Mg-Cu high-strength aluminum alloy ultra-thick plate, and the results have been verified. On the basis of verified simulation parameters, residual stresses in quenched 4000mm×720mm×285mm ultra-thick plate and their reduction through single-side cold compression method were simulated by SIMUFACT software. After quenching, the value of maximum tension stress located at the interior center of the plate is 200MPa, and the value of maximum compression stress located on the surface of the plate is-169MPa. Through analysis of single-side cold compression processes, it can be concluded that more than 90% quenching residual stresses can be reduced by 1% upsetting ratio and 75% feed of the top die. Residual stresses after compression can be reduced down to the range of-25~9MPa. Mean residual stress values of simulation after compression are identical to the XRD testing data.