Numerical Simulation Of Forging Mechanism And Process And Die Design Of Automobile Parts

With the high development of the motor industry, motor performance advances continually. There is a great demand for precise and complex auto parts. For the motor manufacturing, the new products will be the competitive core in the future. The high quality, low cost and short period of the auto parts development are the key factors in wining the auto market. In such cases, new forging processes, material and energy saving processes are very important to the production of new type of auto parts. And the advanced technology of die design will play an important role in improving auto parts design, shortening development period and lowing production cost.In this paper, the processes for both DFL350 piston head and CA6DL piston are analyzed first. Then the three-dimensional FEM models of the warm extrusion process of DFL350 piston head and CA6DL piston are established. The three-dimensional FEA software DEFORM is used for numerical simulation of the warm extrusion processes. The parameters such as forming temperature, friction factor and draft angle are discussed according to the FEM simulation results. The influence of these parameters on forming process is analyzed according to the simulation results. And the forming laws, the distribution of the stress and strain of the workpiece are obtained. The conclusion offers a theoretic foundation for the warm extrusion process design of piston and the optimization of die design. On the basis of the above analysis and simulation, the warm extrusion processes and the die structure designs of the piston and piston head are designed.The three-dimensional finite element software DEFORM is used to perform the hot die forging of the EQ153 steering knuckle. The forming procedure of the preforming, preforging and finish-forging, both for the original and modified process, are performed. The material deformation laws and load-stroke curve are predicted.