NUMERICAL SIMULATION FOR PRECISION ROLL

FORGING OF AUTOMOBILE FRONT AXLE

Jiang Peng

(School of Materials Science & Engineering, Harbin Institute of Technology, Harbin 150001)

Fang Gang

(Department of Mechanical Engineering, Tsinghua University, Beijing 100084)

Hu Furong  Cao Fei

(Beijing Research Institute of Mechanical & Electrical Technology, Beijing 100083)

Abstract: The precision roll forging-die forging for automobile front axle is a plastic working technology of large front axle forging by small rating forging press. The key of this technology is precision roll forging. Roll forging process of front axel includes 4 steps, which is a class successive partial plastic forming. Due to the contact areas between dies and work piece varying in forming, the simulation for this process is very difficult. The FEM (Finite element method) models for 4 process steps are modeled, and the rigid-plastic FEM program DEFO-RM-3D is used to simulation roll forging. Material deformation laws in roll forging are studied, and effects of die geometrical parameters and process design values on forming quality are investigated. Comparison between the computational results and tests results shows that the numerical simulation can predict perfectly the shapes and flaws of workpiece in rolling forging.

Key words: Roll forging  Automobile front axle  FEM  Numerical simulation

CLC No: TG30

国家自然科学基金资助项目(50205013). Received 20041123, received in revised form 20050106