Abstract:In response to the susceptibility of conventional cast wheels to forming defects and the high demand for energy conservation and emission reduction in modern vehicles, a two-stage precision hot forging process was designed to fabricate high-strength and lightweight 7050 aluminum alloy wheels. The hot deformation characteristics of 7050 aluminum alloy billets were systematically examined through isothermal hot compression tests. Finite element models for the pre-forging and final-forging operations were developed via Deform-3D software to conduct full-process numerical simulations of the wheel hub hot forging process and analyze the distribution characteristics of various physical field variables. A mathematical regression model was constructed based on the response surface methodology. Aiming at the dual objectives of reducing forging load and minimizing forging damage, key process parameters including initial forging temperature, die forging speed, and friction coefficient were optimized. The optimization outcomes demonstrated that the peak loads in the pre-forging and final-forging stages were reduced by 22.46% and 13.26%, respectively. The maximum damage zone of the forging was significantly reduced, and the overall damage level was remarkably lowered. Forging experiments were performed under the optimal process parameters, and the forgings exhibited excellent forming quality with comprehensive properties meeting industrial technical requirements.