Research On Finite Element Simulation Of STEYR Forging Process

Automotive steering knuckle is important automotive safety parts. It supports the body weight, transfers steering moment and endures braking moment of front-wheel. It hard to form because of complex structure and high requirement about quality. FEM checks product quality by virtual material process,it can save cost and a lot of time . It is urgent need to solve the problem that how it can be produced efficiently and economically.In this paper, with the STEYR knuckle as the research object. Technique of precision forming of complex components, based on the forming theory of FEM and die forging, and taking into account the characteristics of steering knuckle, madding section to shift the production of new technology and process design of various processes in accordance with die. The process of combined extrusion forming and closed-die forging is studied by three-dimensional thermal coupling FEM analysis with the aid of UG and QFORM. So the metal flow rule and the fields of stress, velocity and temperature can be obtained, as well as the load- distance curve. Reasonable to draw the feasibility of forming process and the existence of defects on the basis of amendments to improve the process dies, re-simulation analysis, eventually forming process more reasonable. The method is also studied by conducting the experiment, which verify the correctness of numerical simulation and the feasibility of this technology. The new technology which realizes forming in steps of extrusion and forge, greatly simplifies the manufacturing of STEYR steering knuckle, reduces the production cost.In this paper, section through the forming process of the shift of the optimal design changes as well as the forming die, the realization of a steering knuckle parts qualified production, improve material utilization, and makes it possible to produce it .Also it provides a viable basis for process parameters and dies design of STEYR knuckle.