The Numerical Simulation And Optimization Of Precision Performing Forge Rolling Process Of Fore Axle

Forge rolling is an important means in metal-forming, the process presents many advantages such as raising the productivity, strengthening the adaptability of the technics, minimizing the investments on equipment and so on. But it is essential to spend many design and debugging time when we develop a forge rolling technology as complex as fore axle. Because the form rule knowledge of forge rolling is at experience phase, and the rolling study achievement can't provide a accurate calculational methods, more than a direction. It is inevitable to modify design parameters frequently and to waste many manpower and resource. With the rapid development of information, traditional means has been replaced by finite element method(FEM) in the course of metal forming. Using the computer and rigid-plastic finite element method, we simulate the forge rolling of fore axle with FEM to understand the rules of the metal flow in forge rolling. We are able to achieve the ideal stress and strain field by adjusting the technology parameters. The FEM has been a powerful tool for optimizing technology projects in the design of the technology and die.In this paper, the fore axle forge rolling technology and the forge rolling die draft are been designed, and parametric forge rolling die models are been built by the Unigraphics(UG) software. The modeling of the forge rolling dies belongs to the typical free-form curve and surface modeling. So we model the forge rolling dies with the power-function UG and bring forward the ideal modeling methods in order to ensure that the parameters in key parts can be modified easily.Based on above all, using rigid visco-plastic material model and thermo mechanical coupled simulation, three forge rolling steps of fore axle are analyzed and simulated with a finite element analysis software DEFORM₃D. In this paper, the problems such as the choice of the die parameters, restriction and contact are answered in detail. Besides, primary technology of corporation is improved by adjusting the position of die parting surface and adding worktables. The technology improvement overcomes the bend disfiguration of forge rolling pieces which result from the asymmetry of forge rolling dies in the condition that the effective stresses and strains are changed appreciably. The thesis solves the problems that the pieces exceed or lag forge rolling dies, caused in the course of simulation, by modifying model parameters of the second forge rolling die.