Research On The Roll Forging Process For The Optimal Blank Of Truck Front Axle

Truck front axle is an important part of the load-bearing.Because of its complex shape,require high strength and stiffness.Big cross section of ups and downs,difficult to directly forging,generally use the system blank roll forging + shaped forging production process,the system blank roll forging formed the basis for forging,but ordinary roll forging billet system just to play simple Dose effect of low quality after the forming roll forging forgings.With the development of roll forging technology,the process of forming the front axle has been steadily progressing,this paper uses preformed roll forging billet manner on the basis of existing forming process,the pre-forming roll forging,front axle beams sites basic shape,a larger portion of the spring installation broadening fist portion roll into a square,to reach the entire forging forging blank size requirements,and then finally shaped by bending and forging a whole.Roll forging preform molding equipment at reduced pressure and can improve the utilization efficiency of the material,and has important application value in actual production.Preformed roll forging technology and die-slot design not only roll forging load,die forgings quality of life and have an important influence on the forging and shaping force subsequent forging process,forging die life and the final shape of the workpiece has a direct relationship.In this thesis,three times the pre-forming process for the production of the front axle roll forging blank forging forming,forging blank and making the front axle roll forging mold design,according to the structural characteristics of the front axle forgings,first identified the Road times roll forging of forging a cross-sectional view and a special,on this basis,the use of 3D solid modeling software UG to design each pass roller forging model;then the mold cavity design according to the characteristics of each of the special structure of the interface,get used to roll forging die forming,the establishment of simulation model;and finally roll forging simulation models into Deform-3D by finite element simulation,the flow of each pass forged metal,variation and temperature variation of stress and strain fields,through analysis of forming process of forging problems,forging die roll is optimized to modify the special parts of the cavity structure,finally get in line with the size requirements of the front axle forging blank.Based on the numerical simulation,orthogonal experiment for the third time in the forming process parameters were optimized,select the bite angle,roll forging angular velocity,friction factor,the initial temperature of the design variables,the maximum forming load and to optimize the maximum broadening indicators,front axle preforming roll forging process parameters,to give the law a different process parameters and the significant degree of influence on indicators,the results were analyzed using a comprehensive balance method to obtain a set of optimal parameter combination,the optimal process parameter combination substituting Deform-3D parameters in combination to verify this through numerical simulation,consistent with the expected results prove the feasibility and accuracy of the theory and simulation methods.