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Study on Heat Treatment Deformation of Magnesium Alloy Cabin and Deformation Restraint with Internal Support Tooling

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Abstract

Severe deformation of GW103k magnesium alloy cabin in heat treatment is easily to cause failure in the subsequent assembly process. Its deformation variation and stress distribution in heat treatment were investigated in this study to acquire the methods for deformation control. Firstly, the finite element model of heat treatment process of castings was established, and the stress and deformation evolution of was obtained. Secondly, the effect of residual stress and structural stiffness on the variation of deformation was analyzed and a method of support tooling was adopted to decrease the deformation in heat treatment. Thirdly, the effect of tooling parameters on the deformation was investigated and a quantitative calculation model was established between the tooling section parameters and the maximum radial deformation of the cabin. And the stress distribution of the cabin has been verified by experiments. The results showed that the local stress reached 130 MPa with heterogeneous residual distribution before heat treatment. The maximum radial deformation reached 5.7 mm after heat treatment. Deformation was induced by the released residual stresses on top of the cabin during the preheating stage. The asymmetric buckling deformation of the top of the cabin was determined by the uneven stiffness distribution. Deformation of the cabin after heat treatment could be effectively reduced by adding the internal support tooling with spoke-shaped on the top end face bumps of the cabin. By the simulation results, when a spoke-shaped tooling with a sectional dimension of 40 mm × 60 mm was used to support the bumps at the top of the cabin, the deformation inhabitation could reach the minimum of 0.8 mm. And the deformation suppression rate reached 85.9%. This work can provide a accurately controlled deformation suppression scheme for similar thin-wall cabin castings.

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Funding

This work was supported by the National Natural Science Foundation of China (grant number 51327902); State Key Laboratory of High Performance Complex Manufacturing, Central South University (Grant Number ZZYJKT2022-04).

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Authors and Affiliations

  1. Light Alloy Research Institute, Central South University, Changsha, 410083, China

    Hai Gong, Long Zhang, Tao Zhang & Bin Yi

  2. State Key Laboratory of Precision Manufacturing for Extreme Service Performance, Central South University, Changsha, 410083, China

    Hai Gong & Tao Zhang

  3. Shanghai Academy of Spaceflight Technology, Shanghai, 201600, China

    Xuliang Zhang

Authors
  1. Hai Gong
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  2. Long Zhang
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  3. Tao Zhang
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  4. Bin Yi
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Contributions

HG: conceptualization, funding acquisition, investigation, writing—review and editing. LZ: writing original draft, methodology. TZ: supervision, project administration. BY: formal analysis, data curation. XZ: resources and validation.

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Correspondence to Tao Zhang.

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Gong, H., Zhang, L., Zhang, T. et al. Study on Heat Treatment Deformation of Magnesium Alloy Cabin and Deformation Restraint with Internal Support Tooling. Int. J. Precis. Eng. Manuf. 25, 1257–1270 (2024). https://doi.org/10.1007/s12541-024-00971-3

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