A Study On Forming Process Of Automobile Triangular Flange

With the automobile industry growing,the property of motors improves constantly,the requirement of automobile parts is more and more strict in terms of industry standard,high strength forgings are more competitive in the market.Therefore,for automobile parts manufacturers,only doing research on high quality,low cost,high efficiency of auto parts can make the manufacturers earn their places in the car market.In this case,the various auto enterprises have an attention to the development of the new forming technology and new materials gradually.Triangular flange is the part of transmission shaft of passenger motor vehicle,which is used to transfer the torque of engine and compound bending load,and it is one of the key and important parts connecting the drive system with spline shaft.The shape of triangular flange is complicated,and there are three branches and convex platform,therefore it is difficult to form and the high requirement of its forming process is needed.It is urgent to solve the problem that how to produce such kind of triangular flange efficiently and economically.In this paper,in order to reduce the production cost as possible,and achieve the purpose of less machining of the forgings,three dimensional rigid visco-plastic finite element model of triangular flange is established based on the theory of hot forging and hot extrusion forming and the characteristics of triangular flange themselves,the process of the forming of triangular flange forging is simulated by using the finite element software DEFORM-3D,comparing the original forging process with the new in details.The die forging process and die shape is redesigned to explore a suitable way of manufacturing triangular flange.In addition,the die stress is analyzed as the die wear and tear to estimate the life expectancy.In this paper,the new forming process of triangular flange on the passenger cars having been developed,and provides an effective way for the localization of triangular flange,while the successful experience of the research process can provide some reference to produce similar flange parts.