Numerial Simulation And Optimization Of Car Rear Axle Forming Processes Based On Dynaform

Drive axle as one of the key components of car, which not only affect the loadbearing and safety of vehicles, but also the comfort. Therefore the properties of drive axledirectly affects the performance of the vehicle. As an important part as bearing and forcetransmission, enough strength and stiffness are needed for drive axle housing,. In view ofimportance of axle housing, computer numerical simulation technology are used forforming process of stamping and welding type axle housing to analyse the main processparameters of the forming processes.Due to unreasonable setting of parameters in the forming processes of stamping andwelding type axle housing, fracture and wall-thickness reduction appear,which wouldhave a bad effect on the usability.Springback appears due to elastic deformation afterforming, and springback values will not affect subsequent processing only in the allowablerange. Design theories of forming processes for axle housing are analysed firstly,in orderto master the forming law of axle housing better. Then, the technologies of axle housingare discussed, and3D models are built by3D modeling software UG. Finite elementmodel of axle housing are built by Dynaform software, after the process of finite elementmodel builded and the matters attention are discussed in detail,the metallic flow regularityand main influencing parameters of axle housing in the process of forming are analysed.Through the method of orthogonal test, the influence of main forming parameters for axlehousing is analyzed, and a set of optimal solutions are obtained. The rationality of housingforming under selected parameters is verified through simulation,and the rupture, thinningand other defects are avoided. Direct at the springback problem of sheet during formingprocess, the reasons of springback and modified measures are discussed detailedly. Inview of the springback problem in the process of sheet metal forming, the causes ofrebound and correction measures are discussed in this paper,and the springback values offorming results under optimal parameters are computed. Results show that, springbackvalues are in the permitted range. Real production can be guided by springback simulationprocesses conducted in this paper. The goal of shortening product development cycle andreducing production cost are achieved...