Forming Process and Optimization of Straight-wall Ribbed Irregular Al-Mg-Zn Alloy Wire Clamps

HU Ning; ZHANG Zhimin; REN Xianwei; LI Zhiyong

doi:10.3969/j.issn.1674-6457.2026.04.003

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (4) : 24-32. DOI: 10.3969/j.issn.1674-6457.2026.04.003

Light Alloy Forming

Forming Process and Optimization of Straight-wall Ribbed Irregular Al-Mg-Zn Alloy Wire Clamps

HU Ning, ZHANG Zhimin^*, REN Xianwei, LI Zhiyong

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Abstract

To solve the problems of severe flash and low material utilization in the current production of a straight-wall ribbed irregular aluminum alloy wire clamp via open-die forging, the work aims to design a forming die with a closed cavity structure and optimize the geometric parameters of the pre-forged part matching the finishing die cavity, achieving precision die forging of the wire clamp. Finite element simulations were carried out in Deform-3D for two forming processes. By optimizing the shape and dimensions of the pre-forged part, the appropriate die structure and pre-forged part geometry were determined. Orthogonal experiments were further conducted to investigate the effects of forming temperature and strain rate on forming load and strain distribution, and the suitable forming process parameters for the aluminum alloy wire clamp were obtained. Finally, the feasibility of the forming scheme was verified through experimental trials. Simulation analysis determined the appropriate shape and dimensions of the pre-forged part and the forming die for the straight-wall ribbed irregular aluminum alloy wire clamp. Orthogonal experiment optimization yielded the optimal forming process parameters for the wire clamp as follows: forming temperature of 450 ℃ and extrusion speed of 1 mm/s, which successfully resolved the issues of excessive flash and insufficient filling of the highest straight wall during forming. Compared with the final formed part obtained from the open-die forging pre-forged part, the closed-die forging process achieved a 31.39% increase in material utilization, a 69.9% reduction in flash area, and a 56.73% decrease in forming load. The finite element simulation optimization results indicate that compared with the open-die forging process, the straight-wall ribbed irregular aluminum alloy wire clamp prepared by the closed-die forging process exhibits higher material utilization, smaller machining allowance area, fuller filling, and lower forming load. The wire clamp is successfully formed on a 1 600 t press, and its dimensions meet practical production requirements.

Key words

Al-Mg-Zn alloy / straight-wall ribbed wire clamp / pre-forged part / plastic forming / numerical simulation / closed-die forging

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HU Ning, ZHANG Zhimin, REN Xianwei, LI Zhiyong. Forming Process and Optimization of Straight-wall Ribbed Irregular Al-Mg-Zn Alloy Wire Clamps[J]. Journal of Netshape Forming Engineering. 2026, 18(4): 24-32 https://doi.org/10.3969/j.issn.1674-6457.2026.04.003

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