| The metal plastic forming process simulation is the key technique which can design reasonable parameters of dies and draw better technical parameters at lower cost with short period, as well as describing the whole forming process. But achieving the numerical analysis successfully depends on various factors: including the shapes of the workpiece and tools, constructive relationship, the friction condition, temperature, velocity of the punch and length of calefaction for workpiece etc.The mature simulation technology can reduce designing and producing cost for the corporation effectively, achieving many data that the routine experiment methods can't measure as well. So it can increase the development energy of the new products and the market competition of the corporation. In the paper, according to the field survey and research in the Hongyang thermal extrusion company in Nanyang , Henan provice, the virtual simulation method was used to research the extrusion process of the half axle, sustentation axle and the car behind bridge, which are produced with the extrusion method in the Hongyang factory. The feasibility of the volume figuration FEM was validated, which can also instruct the design of the fact technics scheme, and thereby decrease the research cycle of new products, reduce the cost and help to enhance the integration competition.In the paper, the current research condition in and abroad was analyzed; and the rigid plastic finite element theory was discussed. Based on the rigid plastic finite element theory, the summary main research works are done as follows:(1) The flow stress, strain characters and their sensitivity to temperature was analyzed. The multiple linear regression method was used to do the numerical fitting of the metal material constructive equation in high temperature. And the numerical fitting formula was used to forecast the constructive equation of the material 20Cr in high temperature, which was used in the following finite element analysis for the car behind bridge.(2) The software Deform2D was used to simulate the process of thermal extrusion of the car half-axle. And a group of optimized technological parameters were gained by analyzing the warm-up temperature, extrusion velocity and friction coefficient which was affected to distortion force and the shape of the product, which validate the facticity of bulk figuration FEM.(3)The two-step figuration technology was used to simulate the produce process of the car sustentation axle. The technics scheme and technics parameters of the car sustentation axle for hot extrusion were analyzed and optimized, and then achieved the perfect shape of the car sustentation axle. The two-step figuration technology related in the text can reduce materials, and also reduce work time and improve the manufacture efficiency greatly.(4)It is very uncertain to carry out the figuration of the car behind bridge with the thin steel tube. In the practical experiment of the factory, the phenomenon of metal material stacking usually appears too, which result in the extrusion process failing to carry through. In the paper, the two-step figuration of the car behind bridge was simulated and researched. The influence of the length heated up, friction coefficient and extrusion velocity was researched. Considering the influences of each factor, a group of optimized process parameters were achieved by using the single target optimizing method. And the parameters can instruct the actual hot extrusion of the car behind bridge.
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