Transactions of Materials and Heat Treatment

Title：Finite element simulation of whole process and process optimization on front axle forming for heavy truck

Authors： Zuo Lei Zhang Wei

Unit： Mechanical and Electrical Engineering Department Chongqing Industrial School Electronic and Information Department Chongqing Light Industry School

KeyWords： front axle of heavy truck die forging roll forging folding insufficient filling

ClassificationCode：TG316

year,vol(issue):pagenumber：2022,47(11):55-61

Abstract：

In order to solve the defects such as folding and insufficient filling of front axle forgings for heavy truck, the whole forming process of front axle for heavy truck was studied by finite element numerical simulation and process optimization. Then, based on the empirical data and forging die design theory, the mold of each pass was designed, and the corresponding finite element model was constructed. The results show that in the pre-forging step, the regions at both ends of billet first contact with the mold so that the material flows to the central region, and the billet of I-beam in the central region is extruded and unstable. Furthermore, the material flows upward or downward and bends, causing the material offsets and flows to the flash region, resulting in the lack of material in the middle I-beam region, which in turn causes the insufficient filling defect of I-beam region. However, by reducing the length of the billet I-beam region, there is no obvious bending deformation in the middle I-beam region before contacting with the mold, and the insufficient filling defect is avoided. Due to the relative slip between billet and roll forging mold, the billet is not symmetrical at the central region after roll forging, and the thin edge phenomenon occurs during the second pass of roll forging, resulting in folding defects in the subsequent die forging step. By controlling the distance between the end face of billet and the roll center to offset the roll forging position error caused by the slip between roll and billet in the roll forging process, the thin edge phenomenon and the folding defect are avoided. Thus, using the optimized process parameters for actual production, the surface quality of the front axle forgings is good, and there is no defects such as folding and insufficient filling.

Funds：

2019重庆市教委科学技术研究项目(KJQN201904001)

作者简介：左磊(1972-)，男，本科，高级讲师，E-mail：406666051@qq.com

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