Modeling and Simulation of Mg AZ80 Alloy Forging Behaviour

Magnesium AZ80 is a medium strength alloy with good corrosion resistance and very good forging capability which offers an affordable commercial alternative to the Mg ZK60 alloy used for wheels in racing cars. Extending the market of Mg AZ80 alloy to automotive wheels requires a better understanding of macro- and micro-properties of this structural material, especially its forging behaviour. In this study the deformation behaviour of Mg AZ80 alloy is characterized by uniaxial compression tests from ambient to 420°C at a variety of strain rates using a Gleeble 1500 simulator. A constitutive relationship coupling materials work hardening and strain rate and temperature dependences is calibrated based on test results. This flow behaviour is input into a finite element model to simulate the forging operation of an automotive wheel with ABAQUS codes. The results of the simulation will be used to identify parameters which can help optimize forging and predict possible defects resulting from the process.