The Parametric Design Of Roll Forging Die And Optimized Research For Forging Process

Roll forging is a new technology which is introduced by the longitudinal rollingforging and continuous development in rencent decades.It presents many advantagessuch as raising the productivity,high utilization rate of materials,good forgingquality,minimizing the investments on equipment and so on. With the development ofmanufacturing industry in advanced manufacturing technology, using the roller forgingis becoming more and more popular.However, the deformation of the blank is complexwhich compared with other technology in the roll forging process and die design,thecalculation is complicated as well.Under this circumstance, the period of the die designwas delayed. The die needed to test and repair again and again.From what has beenmentioned above,this technology is greatly limited. Along with the computertechnology and the rapid development of the finite element analysis, the roll forgingCAD integrated system is urgent to develop in order to improve the efficiency andaccuracy of die design. With the numerical simulation software was used to predict andcontrol the roll forging quality and reseach the deformation mechanism of roll forgingprocess.These reseaches has gradually become one of the strategy direction by theengineering personnel in the manufacturing.Based on a certain type of front axle schedule drawing, in the roll forging and rollforging die design process, analysing each section and its spatial relations. Then usingparametric design on each section’s dimensions,as well as the distance between everytwo sections. Using powerful3D software---UG NX to generate solid modeling whichare roll forging and roll forging die. Combined with the method of UG expression andthe tools of the UG secondary development including UG/Open MenuScript, UG/OpenUIStyler, UG/Open API and Visual C++6.0to develop3D parametric design system ofthe automotive front axle roll forging die. Based on above all, combined with this rollforging CAD system to create numerical simulation model, using rigid visco-plasticfinite element analysis method to fulfill each roll forging steps of front axle’s numericalsimulation through DEFORM software. According to the consequence of the numericalsimulation, study the flow rules of metal,the stress and strain field, the load and torquerules in three directions and the temperature field under the three-dimensional deformation state of roll forging. Lastly, The billet of roll forging die for the front axlespring seat section fillet values, roll forging die angular velocity, the friction factor andthe initial temperature of billets are adopted by the orthogonal experimental designmethod, taking use of these four factors of three levels for studying the billet of frontaxle roll forging die structure and process. Analysing the effect of front axle rollforging’s maximal forming load.Through the study of this subject, on the one hand,the engineering designers usingthis roll forging die of3D parametric design system can become faster and more easilyin design roll forging die’s three-dimensional digital model.Meanwhile, the efficiencyof the die design and accuracy rate is increased.On the other hand, the front axle blankroll forging simulated with a finite element analysis by Numerical simulation softwareand then optimizing the forging process to reduce the commissioning and the test of thedie’s working time, improving the roll forging die service life as well. In conclusion,theresearch of this paper integrates front axle roll forging die design、the technology of theCAD parametric design and numerical simulation together, we can derive a lot ofbenefits from this research because it plays a very good role in production and processanalysis.