Skip to main content
SpringerLink
Log in

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

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Zhang CJ (1986) Technology of Roll Forging. China Machine Press

  2. Hu ZH, Hua L (2010) Technology of rotary Metal Forming. Chemical Industry Press

  3. Cai ZY (2005) Precision design of roll-forging die and its application in the forming of automotive front axles. J Mater Process Technol 168:95–101

    Article  Google Scholar 

  4. Tian Y, Guo YH, Wang ZD, Wang GD (2009) Analysis of rolling pressure in asymmetrical rolling process by slab method. J Iron Steel Res Int 16:22–38

    Article  Google Scholar 

  5. Yoo UK, Lee JB, Park JH, Lee Y (2010) Analytical model for predicting the surface profile of a work piece in round-to-2-R and square-to-2-R oval groove rolling. J Mech Sci Technol 24:2289–2295

    Article  Google Scholar 

  6. Li RX, Jiao SH, Wang JL (2012) Roll- forging technology of automotive front axle precision performing and die design. IERI Procedia 1:166–171

    Article  Google Scholar 

  7. Park JJ, Oh SI (1990) Application of three dimensional finite element analysis to shape rolling processes. J Eng Ind 112:36–46

    Article  Google Scholar 

  8. Heislitz F, Livatyali H, Ahmetoglua MA (1996) Simulation of roll forming process with the 3-D FEM code PAM-STAMP. J Mater Process Technol 59:59–67

    Article  Google Scholar 

  9. Hong S, Lee S, Kim N (2001) A parametric study on forming length in roll forming. J Mater Process Technol 113:774–778

    Article  Google Scholar 

  10. Kim SY, Im YT (2002) Three-dimensional finite element analysis of non-isothermal shape rolling. J Mater Process Technol 127:57–63

    Article  Google Scholar 

  11. Knapiński M (2006) The numerical analysis of roll deflection during plate rolling. J Mater Process Technol 175:257–265

    Article  Google Scholar 

  12. Xia H, Guo XL, Ji CC (2012) Numerical Simulation of Blank-making Roll Forging Process for Heavy Automotive Front Axle. Proceedings of 2012 International Conference on Mechanical Engineering and Material Science, pp 481–484

  13. Zhou J, Xiao C, Yu YY, Jia Z (2013) Influence of tool parameters on tool wear in two-roll cross-wedge rolling. Int J Adv Manuf Technol 65:745–753

    Article  Google Scholar 

  14. Capece Minutolo F, Durante M, Lambiase F, Langella A (2006) Dimensional analysis of a new type of groove for steel rebar rolling. J Mater Process Technol 175:69–76

    Article  Google Scholar 

  15. Kim W, Kawai K, Koyama H, Miyazaki D (2007) Fatigue strength and residual stress of groove-rolled products. J Mater Process Technol 194:46–51

    Article  Google Scholar 

  16. Sedighi M, Mahmoodi M (2009) An approach to simulate cold roll-forging of turbo-engine thin compressor blade. Aircr Eng Aerosp Tec 81:191–198

    Article  Google Scholar 

  17. Sedighi M, Mahmoodi M (2012) Pressure distribution in cold rolling of turbo-engine thin compressor blades. Mater Manuf Process 27:401–405

    Article  Google Scholar 

  18. Byon SM, Na DH, Lee Y (2009) Effect of roll gap adjustment on exit cross sectional shape in groove rolling-experimental and FE analysis. J Mater Process Technol 209:4465–4470

    Article  Google Scholar 

  19. Zhou J, Zhi J, Liu H, Wang MH (2013) A study on simulation of deformation during roll-forging process using system of special shaped and hat groove. Rev Adv Mater Sci 33:354–359

    Google Scholar 

  20. Jia Z, Zhou J, Ji JJ (2014) New type of groove used to improve friction in roll forging. J Cent South Univ 2:493–499

    Article  Google Scholar 

  21. Yan Y, Wang HB, Li Q, Qian B, Mpofu K (2014) Simulation and experimental verification of flexible roll forming of steel sheets. Int J Adv Manuf Technol 72:209–220

    Article  Google Scholar 

  22. Hu YM (2011) The special forging technology. National Defense Industry Press

Download references

Author information

Authors and Affiliations

  1. School of Materials Science and Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Wuhao Zhuang & Liying Dong

  2. Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan, 430070, China

    Wuhao Zhuang, Lin Hua, Xiaowen Wang, Yanxiong Liu, Xinghui Han & Liying Dong

  3. Hubei Collaborative Innovation Center for Automotive Components Technology, Wuhan University of Technology, Wuhan, 430070, China

    Lin Hua, Yanxiong Liu & Xinghui Han

Authors
  1. Wuhao Zhuang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Lin Hua
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xiaowen Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yanxiong Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Xinghui Han
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Liying Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Lin Hua.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhuang, W., Hua, L., Wang, X. et al. Numerical and experimental investigation of roll-forging of automotive front axle beam. Int J Adv Manuf Technol 79, 1761–1777 (2015). https://doi.org/10.1007/s00170-015-6905-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-6905-9

Keywords

Search

Navigation