Numerical Investigation on Semisolid Closed-Die Forging of 6061 Aluminum Alloy Scroll Plate Based on the Arrhenius Constitutive Model

As a key structural component of scroll compressors, the forming quality of the scroll plate directly affects overall performance. To address the issues of high forming load and poor rib filling in conventional processes, this study investigates the semisolid closed-die forging of 6061 aluminum alloy through numerical simulation. Semisolid rheological data were obtained from high-temperature compression tests. We also formulated an Arrhenius-type constitutive model to predict material behavior. This model proved highly reliable, achieving a correlation coefficient of 0.99547 and keeping the average absolute relative error down to 3.67%. By employing both orthogonal experiments and simulations, we evaluated how different process parameters impacted the outcome. This analysis ultimately yielded an optimal parameter combination: a die temperature of 350°C, a billet temperature of 600°C, and a punch velocity of 10mm/s. Under these conditions, the forming load, flow behavior, stress–strain distribution, and temperature evolution were analyzed. The results show complete rib filling, uniform deformation, and absence of defects, providing theoretical guidance for industrial applications of semisolid closed-die forging of scroll plates.