Multi-pass Forging Process Study And Numerical Simulation For Automotive Steering Knuckle Arm

Automotive steering knuckle arm is one of the safety parts, which to achieve load and guidance functions in the car is running. Their work more complex operating environment, the use of security and reliability requirements can be very high. The traditional forging process design mainly rely on the experiences of trial and error design, the lack of a clear steering knuckle arm forging metal in the process of the flow in the mold, often caused by an unsuitable design billets, forgings there folding patterns, lack of meat and other defects, low die life. With the computer technology and numerical calculation methods development, as represented by the finite element method numerical simulation technique has been widely used in analysis of metal forming processes.In the paper, based on the hot forging forming theory, take HF6700 steering knuckle arm of light truck as the research object, the main research contents are as follows:1. By analyzing the structural characteristics of steering knuckle arm forging, combined with the original technique proposed roll forging-friction press forging process, that is, baiting→medium-frequency induction furnace heating→Roll forging billet (2 times)→630t friction screw press bending→1000t friction screw press for the final forging→hot side cut→hot correction.2. Using finite element simulation software, established a three-dimensional coupled thermo-mechanical model and taken the finite element simulation for multi-pass forging process of steering knuckle arm. Through simulation and optimization of the system blank of blank shape and size, obtain the metal flow distribution of roll forging, pre-bend, and finally forging, analysis of each pass of the strain field, stress field, velocity field and forming load and so on, for mold design and the actual manufacturing operations provides the basis and reference.3. Based on the Archard wear model, research the law of the final forging die when the preheating temperature Tpre, friction factor m and the initial die hardness of HRC on the influence of the amount of die wearing, and predicted die life for the last forging die.