Title: Research on simulation and prediction of extrusion defects of automotive parts

Authors: Wei-Hong Zhang, Zhou-De Qu, Ming Cheng, Shi-Hong Zhang, Zhong-Tang Wang, Yi Xu, Qiang Wang

Addresses: Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China. ' Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China. ' Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China. ' Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China. ' Department of Materials Science and Technology, Shenyang Ligong University, Shenyang 110168, China. ' Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China. ' School of Mechanical Engineering, Jinan University, Jinan 250022, China

Abstract: Taking the forming processes of half-shaft bushing, wayshaft, and starter socket as examples and aiming at the typical problems in extrusion of automotive parts, some defects such as folding, underfilling, and cracking were numerically simulated and predicted in this paper with rigid-plastic FEM, rigid-viscoplastic FEM, and thermo-mechanically coupled methods by means of DEFORM3D. The distribution laws for the stress, strain, velocity, and temperature in the forming processes were analysed. The reasons for the defect generation were discussed, and some optimum measures for these processes were put forward. The results agree well with the experiments. Several proposals for prediction and simulation of extrusion defects of these automotive parts are put forward. It was instructional to apply FEM to the quality control of the extrusion.

Keywords: extrusion defects; numerical simulation; half-shaft bushing; wayshafts; starter sockets; folding; underfilling; cracking; metal extrusion; metal forming; automobile industry; automotive parts; FEM; finite element method; stress distribution; strain distribution; velocity distribution; temperature distribution; quality control.

DOI: 10.1504/IJVD.2005.007219

International Journal of Vehicle Design, 2005 Vol.39 No.1/2, pp.62 - 72

Available online: 24 Jun 2005 *

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