Roll Forging Technology and 3D Finite Element Simulation of Automobile Front Axle
According to the characters, technological condition and requirements of automotive front axle forging, the advantage of the roll forging and integral die forging complex process for automobile front axle were explained, including the determination of roll- forging parts chart, selection of billet dimension, decision of roll- forging steps, special roller- shaped design of typical section, and the front sliding parameter is calculated, its effect to length of forging parts gets analyzed. In this paper, taking NHR front axle as an instance, both the process of exact roll- forging billet and die design are studied, as the result, roll- forging die、 performing roll- forging die and final roll-forging die are design respectively. The process for roll forging was simulated by the three dimensional finite element analyses under isothermal condition, and metal flow procedure and force time curve were obtained. The connection among metal flow law and die cavity design and forming load were also analyzed. To verify the reliability of the simulation, the results for profile was compared with the tested forging part, showing that metal flow law of both are coincident and FE simulation of roll forging is accurate. Practice testify that FE simulation of roll forging for front axle can reduce the time of process design and procedure debugging and be helpful to response the market demand.
Mingjin Chu, Huizhong Xu, Zhilin Jia, Yun Fan and Jiangping Xu
R. X. Li and S. H. Jiao, "Roll Forging Technology and 3D Finite Element Simulation of Automobile Front Axle", Applied Mechanics and Materials, Vols. 178-181, pp. 2845-2849, 2012