Research on the casting–forging precision forming process of alternator poles

Because of the defects exiting in current manufacturing processes of alternator poles, such as more material demand, higher forming force and lower accuracy, a casting–forging precision forming process of alternator poles was developed and investigated in this work. In the process the pole was produced by casting and closed die flashless forging. It cannot only shorten process, decrease material and power demand, but also increase the accuracy of the forgings. The forming processes was investigated by testing and numerical simulation. The result can provide a basis for applying the process in practice.