Fine Big Drop Front Axle Roll Forging Billet System - Die Forging Process Research Overall

. Portal Axle,as the low-floor city-bus’s main forged part, has higher requirements on thestrength, impact resistance, anti-fatigue performance. Precision roll forging billet wholeforging axle technology greatly reduce the tonnage of forging equipment, improve materialutilization rate, saving the cost of production, the front axle is not the big drop forging. Thispaper studies the drop front axle precision roll forging billet-integral die forging process,have important sense to the actual production.The big drop front axle main forming process: three steps of the fine roll forging billet,bending, forging. In the process of precision roll forging billet is a new process between theroll forging billet and the forming roll forging, closer to the forming roll forging, roll forgingstill need further overall forging forming, can guarantee the quality of forgings and precision;the integral die forging process without material head, improve the utilization rate ofmaterials.There were many technical difficulties in precision roll forging billet such as bendingparts of a larger gap, inhomogeneous deformation, pressure distribution, the amount offorward slip value selection, blank and die groove longitudinal meshing, complex sectionfilling shape.This paper discusses the structural characteristics of the front axle and big drop.To simulate that meet the bending, forging, roll forging which is suitable for roll forging;design the section cavity for each different character parts; pressure distribution of selection,forward slip value, width and other parameters of the billet and dies; each groove longitudinalmeshing problems.On the basis of the above research, the parametric modeling of UG software on the threeroll forging die, be convenient for mould parameter modification, finite element numericalsimulation is carried out on the big drop front axle precision roll forging billet whole forgingprocess simulation software with DEFORM-3D, carry on the study and find solutions, such as:folding, scraping intermediate‘I beam’discontent, blank and die cavity longitudinal meshingmismatch and roll bending does not satisfy the forging problem and so on.Optimization by simulated die parameters on the big drop front axle precision rollforging billet whole forging and simulation parameters, and analyzed the forming process ofmetal flow, die load, stress field, temperature field and other information and data. In practical production, providing analog level basis and guide the selection of process, die design,equipment selection.The results show that, the selection process with Ф1000mm roll forging machine and4000t friction press machine, as the main equipment for forming.