| Automobile lightweight technology is the important measures to realize energy conservation and emissions reduction.Under the premise of ensuring the strength of the structure,the realization of the front axle lightweight for the optimization of vehicle performance,reduce fuel consumption and pollutant emissions,has obvious economic and environmental value.Front axle is an important part of the chassis system,directly related to vehicle safety and operational stability,its mechanical properties and manufacturing accuracy requirements are extremely high.In order to manufacture high-performance lightweight automotive front axle,its forming process research is essential.The main research contents are as follows:The lightweight structure of a front axle product is improved,and the force of the front axle is analyzed to verify whether its mechanical properties meet the requirements.Structural improvement of the front axle of the car on its forming process put forward higher requirements,lightweight automotive front axle forming more difficult.Therefore,the precise manufacture of lightweight front axle,need to study the process of automobile front axle manufacturing process parameters on the formation of the law and micro-organizational changes.The precise manufacture of lightweight front axles is inseparable from the selection of suitable forming process parameters.The finite element model is established,and the finite element simulation of the first pass roll forging is carried out.The dimensions of the forging are compared and the accuracy of the model is verified.The effects of four key process parameters(the initial temperature of the blank,the speed of the roll forging machine,the friction factor and the fillet angle of the mold spring plate)on the first pass of the roll are studied.The influence of each process parameter on the maximum forming load of the first pass was studied by orthogonal test,and the parameters of the front axle forming process were developed.The method of finite element analysis and experiment is used to study the microstructure of roll forging process.The deformation ratio,elongation and the equivalent strain distribution of each blank were studied under the condition of two groups of process parameters.The change of microstructures of blanks during roll forming process was simulated by finite element method,and the change of microstructure in roll forging process was analyzed.The best shape of the forging process parameters was obtained by comparing the shape of the forging and the grain condition under the condition of two different process parameters.The change rule of the shape and temperature of the blank before the forming process of the automobile is studied by using the finite element method,and the front axle forming process is established.The numerical simulation of the shape,temperature field,equivalent strain and forming load of each sub-process is carried out by analyzing the front axle forming process.Based on the best process parameters to develop the actual production experiments to verify the feasibility of structural improvements.Provide technical support and guarantee for the development of high-performance lightweight front axle products. |
