CAE Optimization Of The Forging Process Of Automobile Steering Knuckle

Steering joint is one of the main parts in the automobile front axle assembly, it is an important security part in the automobile. It supports the bodywork, transfers the turning moment, and withstands the brake moment of front wheel. The requirement to its mechanical performance and structure is very strict, and it is difficult to manufacture steering joint. It is the main problem that how to adopt the effective and low-costing method to produce the high quality steering joint.In the paper, Pro-E and Superforge software are applied to simulate the forging process of steering joint according to the extrusion and die forge theory. In order to improve the forming accuracy of steering joint, save material and increase the life of die, the forming process of steering joint is simulated using FEM. According to the simulation results, the die forging technology is improved and optimized, the new forging technology is more rational than the original technology. In the process of optimizing the forging technology, the performing billet shape of compound extrusion and the open-die forging process are simulated by the thermal coupling finite-element analysis, the metal flowing rule, stress, strain, speed and temperature fields are attained by FEM simulation, the curve of stroke-load is also gained. The influence of forging parameters to the metal flow, forging force and temperature fields are researched in the paper, the main forging parameters are decided according the FEM results.In order to validate the simulation results, the experiment of forging steering joint is done in Shandong Guanyue Group. The comparison shows that FEM simulation results are consistent with the experiment results, the optimized parameters of forging steering joint are accurate and dependable. The new technology presented in the paper can finish two forging steps in one hot-forming crank press, so the machining process of steering joint is simplified, the cost is reduced. A new effective method of machining steering joint is given.