Roll forging process and flowing characteristics of automotive front-axle forges with a complex and variable section

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Roll forging process and flowing characteristics of automotive front-axle forges with a complex and variable section

Zhang Chunjiang / Tai Yuzhu / Qiao Guang / Zhang Changchun

The front axle is an important component of an automobile. Since it supports a heavy load, it should have enough strength, rigidity ad fatigue life. Compared with simple forges, it is difficult for the front axle to be roll-forged because of not only its complex shape but also the abnormal variable section in its longitudinal and lateral directions. The metal forming and flowing during the rolling of the front axle have many characterized features. The front axle is the biggest and most complicated forge that has been roll-forged successfully in China so far. In this paper, the first part briefly introduces the rolling process of the front axle. The second part analyzes some of the key problems of metal deformation and flowing in axle rolling. These problems include uneven deformation, metal implicating and transfering, advance or delayed deformation in different parts of a section, stability conditions of rolling deformation, factors that affect metal filling and so on. The third part discusses the method used for solving these technical problems in front-axle forging.