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A 3D finite element (FE) model of the preliminary roll forging process for the automobile front axle was established, and the numerical simulation was conducted by the Deform-3D platform. Then, a reasonable boundary condition was confirmed by comparing the simulation result with actual roll forging of front axle, and its accuracy was verified. The analysis shows that the error between the simulation and experimental results is the smallest with friction factor of 0.6 and heat transfer coefficient of 11. It was analyzed the influences of the heat transfer coefficient, friction factor, initial temperature of billet, rotational speed of roll forging, die fillet of spring on the preliminary roll forging process of automobile front axle beam. The results show that when the friction factor and the initial temperature increase, the center distance of spring and the maximum width increase. As the rotational speed increases, the center distance of spring and the maximum width gradually decrease. The general forging length and the maximum width decrease with the increase of die fillet. Thus, through the optimization of the preliminary roll forging process, the final forging load is reduced, and the utilization ratio of material is improved.
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