Front Axle Fine Roll Forming Process Of Three-dimensional Finite Element Numerical Simulation,

Rolling forging is an important means in metal-forming method. Nowadays, it is possible to do complex rolling forging simulation with advanced computer. The research on full-scale rolling forging process by numerical simulation can help us to control the production quality and to understand the true physical mechanism.It is difficult to produce the automobile front axle with precision forming rolling forging technology. Furthermore, the design parameter of rolling forging die is acquired from mechanical design handbooks and experiential formula. So the theoretical design method is different from practical condition .These bring some problems in manufacture and make us spend much time to adjust the dies and modify it more times. Using the computers and the rigid-plastic finite element method, we simulate the rolling forging of automobile front axles with 3-D FEM to understand the rules of the metal flow in rolling forging. We are able to achieve the ideal stress and strain fields by adjusting the parameters of the manufacture technics and product dies.Those are important to direct the design of the rolling forging dies.The modeling of the rolling forging dies is different from that of the other numerical simulation. It belongs to the typically free form face modeling.lt easy give birth to unparameters in modeling, which makes boole operation fail. So we model the rolling forging dies with power-function UG and bring forward the ideal modeling methods.It is more important to know how to adjust the rolling forging parameter in order to get a good rolling forging quality. In this thesis, some optimization results are concluded by DEFORM simulation, and the influence of these parameters is evaluated. Some valuable results can guide the future simulation and production.In this thesis, we solved some technology problems, for example the choice of the die parameter , restriction and contaction, and systemically research the characteristic of the stress and strain field in the first and second working procedure. It is more important to gain some vital parameters of the engineering application and relations between the stress field and the strain field in rolling forging. The thesis alse put emphasis on analysing the rules of the load and torque development in the third and fourth working procedure in order to understand the characteristic of the load and torque in x,y,z axis, all of which help us to solve some practical problems in workshop.