Numerical Simulation On Automobile Hub Spinning Forming Process

Hub is one of the most important parts in automobile running system, it supports the body weight, embodies appearance design, turns the direction and drives the automobile, etc. The spinning is an advanced manufacturing technology method synthesizing with the process characteristic of forging, extruding, drawing, bending and rolling. It is widely applied in the field of precise processing technology of aerospace, mechanical, autos and chemical industry due to its good forming performances. As an advanced manufacturing technology, spinning is also applied widely in the automobile hub production. The automobile hub spinning is a very intricate plastic forming process. To study the forming law of automobile hub spinning, the spinning process has been investigated by computer numerical simulation combining with theoretical analysis in this paper.The reasonable mechanical model that fit well with the real process of spinning has been established by means of finite element theory and process characteristics of automobile hub spinning. The four-node quadrilateral element has been used for plotting the blank, mandrel and roller have been discreted respectively, boundary condition, friction condition and movement track of roller have been obtained. The forming processing of automobile hub spinning has been simulated numerically with the forming software DEFORM in this paper. Deforming grid of spinning blank in the varied pass of spinning forming has been determined, the curves of forming taken with every pass have been presented, the distribution regulation of stress and strain of forming zone and plastic deformation mechanism of hub spinning have been analyzed. It is the useful theoretical basis to research rub spinning process and optimize the process parameter collectedly.The automobile hub spinning of different process parameter has been simulated in this paper. The effects of various parameters such as nominal drawing coefficient, relative wall thickness of blank, radius of roller's round corner and feed ratio on equivalent stress, equivalent strain and spinning forces have been obtained. Based on these results, several quality defects such as surface wrinkling, blank unfit with mandrel have been studied when automobile hub is spun, and the reasons for them have been put forward.The appropriate process parameters have been selected by basing on the results of the numerical simulation. By using orthogonal design method in the distribution of those parameters, this paper has carried out optimizing the process parameter. In virtue of the degree of spinning force and wall thickness deviation, the influence of spinning forming quality which was bought about by nominal drawing coefficient, relative wall thickness of blank, radius of roller's round corner and feed ratio have been studied with the method of orthogonal experiment. The best appropriate matching process parameters have been achieved in the field of the elective parameters.