Process Optimization Of Thrust Rod Ball Head On Heavy Duty Vehicle Air Suspension System

The heavy vehicle air suspension system can make the automobile driving cab vibration weakened greatly, improve the stability and comfort of the cab, and protect the way effectly. As an important component of the thrust rod guide mechanism of heavy vehicle air suspension system, its role is to prevent the bridge displacement, longitudinal force and lateral force transfer vehicle, and transfer the other direction of force and moment.The text firstly introduces the research status of domestic and international air suspension system and the existing problems; then analyzes the shortcomings and problems of the forming process of the original casting thrust rod ball head during the use; later according to the structure characteristics of the ball head, designed its radial extrusion process and simulate its extrusion process by the element software; finally, though the physical simulation test to simulate the ball head forming process. The specific steps are as follows:(1) Analyzed and discussed the casting process of thrust rod ball. Analysis its casting process, and discussed the advantages and disadvantages of the casting process from the failure of the thrust rod, demonstrate the necessity of turn into extrusion process.(2) Designed radical extrusion of the trust rod ball head. Combined with the ball head structure characteristics, according to the material, blank shape, extrusion temperature, extrusion speed, lubrication etc. technological angle to design the radial extrusion process plan and process parameters.(3) Analyzed the thrust rod ball head radial extrusion forming process by finite element. Though Pro/e three‐dimensional mapping software to modeling and using Simfact.forming finite element analysis software to simulate the ball head extrusion forming process. Analysis metal flow, equivalent stress and strain’s distribution, damage distribution, temperature field distribution and deformation load temperature’s variation during extrusion process.(4) Optimize the thrust rod ball’s extrusion process and then analysis it by extrusion. According the problems appeared in the finite element to optimize ball’s process, by changing the end angle and clearance between punch and die size, to analyze the influence of different parameters on the load, the equivalent stress distribution, damage distribution, and then determine the optimal scheme.(5) Die design. Combination with the ball’s extrusion process scheme and result of finite element numerical to design the ball’s radial extrusion die.(6) Done physical simulation experiment for the thrust rod ball head. Simulated the radial extrusion process by Pb sample, verify whether the ball forming process of metal flow and forming effect are consistent with simulation or not. Though a series of process design, finite element analysis and experiment, got the best scheme of ball head’s radial extrusion process, laid the foundation for the application and popularization of the thrust rod ball head the new forming process.