Simulation And Experimental Study On Forming Process Of Aluminum Alloy Knuckle

With the high development of the automobile industry, automobile performance advances continually. New forging processes, material and energy saving processes are very important to the production of new type of auto parts.Steering knuckle is one of the most important car key parts and a safety part. It supports the body weight, transfers steering moment and endures braking moment of front-wheel. The requirement of its mechanical characteristics and contour structure is so strict that it is very hard to produce. It is urgent need to solve the problem that how it can be produced efficiently and economically.In this paper, the forging process of steering knuckle is analyzed and in order to improve the forming accuracy of this part, save material and increase the life of die, the forming process of steering knuckle is simulated using FEM. The main parameters of pre-forging process and final forging is obtained. This three-dimensional finite element software DEFORM-3D is used to perform the hot die forging of the car steering knuckle. The forming process of the performing, pre-forging and finish-forging for the steering knuckle can be analyzed. The material deformation laws and load-stroke curve are predicted. The distribution of the stress and strain in workpiece is obtained.The technology of forging, FEM simulation and mould CAD are integrated through this research. It helps to shorten developing period, improve life of die, and cut down the cost, etc. the progeny of the research can provide accordance for other mechanical parts and be used to guide producing directly.