Study On Numerial Simulation And Optimization Of Steel Wheel Rim Rolling Processing

Rim processing have the characteristics of complex cross-sections, numerous process parameters and the complicated processing steps. Conventional analysis of wheel rim roll-forming process is a method of debugging which cost a long time and lots of manpower and material. Obviously, it is not applicable for new industry’s requirement today. The development of CAE, CAD and CAM offer new method to engineer study. The application of finite element analysis in high-strength steel rim roll-forming process, can not only test the forming process performance, but also study the sensitive factor and verify the study results conveniently. These means can optimize the process parameters and improve the forming quality. What’s more, compared with traditional analysis method, finite element analysis reduce design costs greatly and improve design speed.This paper analyzes the roll-forming process of22.5x9steel wheel rim, identifies the distribution of shape in three roll-forming, and studies the method of building finite simulation of rim roll-forming in ABAQUS. There is a detailed study of simulation sets including modeling, meshing, material definition, cross-sectional property definition, algorithm selection, set of time step, contact definition, and load application. Based on those sets, the rim-rolling finite simulation is built.According to the characteristics of the rim roll-forming processing, the results of simulation are analyzed in three contexts:energy, stress and shape quality. The analysis of the curve about the ratio of the kinetic energy and the internal energy states that this processing is quasi-static, to ensure that the section of technological parameters and load is appropriate. In the study of equivalent stress distribution in blank, the maximum equivalent stress appearance is the emphasis and the maximum equivalent curve is built to help us summarize the regularities of forming. During the study of thickness changing curve, we find the maximum thickness thinning is the corner of groove which is next to flange. We also find that the most of thickness reduction is concentrated in the first rolling. During the study and optimization of the path in first rolling, we smooth the path of the beginning and end of the feed. We also change the path loading from one-time loading to twice-loading which improve the maximum reduction of thickness. During the study of influence of friction, we find that if the friction factor is chose between0.3and0.35, the shape quality will be improved. During the study of influence of feed speed, we find that the feed speed has little impact on shape quality, which means we only choose the feed speed to ensure quasi-static so that we can accelerate the feed speed to improve efficiency.