Numerical and experimental investigation of roll-forging of automotive front axle beam

摘要

Roll-forging process, an innovative local plastic deformation process, is very suitable for forming the automotive front axle beam. Due to the complicated geometry of automotive front axle beam and the complicated roll-forging process, it is difficult to develop an accurate FE model of roll-forging of automotive front axle beam. In this paper, an experiment of roll-forging of automotive front axle beam is carried out. By comparing the simulation results with the experimental ones, the reasonable friction factors between the dies and roll-forged pieces are determined, so that an accurate 3D FE model of roll-forging of automotive front axle beam is developed under the Deform-3D platform. Based on this accurate 3D FE model, the forming laws of roll-forging of automotive front axle beam are illustrated, which includes the geometry development, effective strain distribution and evolution, temperature distribution and evolution, roll-forging load evolution, and metal flowing velocity distribution and evolution. The research results have important significance for comprehensively revealing the macro-deformation laws of roll-forging of automotive front axle beam.