Finite element simulation and experiment verification of rolling forming for the truck wheel rim

Fang, Gang; Gao, Wenjing; Xiaoge, Zhang

doi:10.1007/s12541-015-0200-4

Cited by 10 publications

(4 citation statements)

References 17 publications

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“…Roll forming is an advanced cold forging process, The forming process is complex, including rounding, welding and slagging, flaring, one-pass rolling, two-pass rolling, three-pass rolling, expansion finishing and Inflatable door holes and other processes [11]. However, the deformation of the rim mainly occurred in the process of three-pass rolling.…”

Section: Rolling Processmentioning

confidence: 99%

Simulation Analysis and Optimization of Rolling Process of Steel Rim

Lv¹,

Mao²,

Li³

et al. 2021

WJM

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In order to solve the problems of rolling forming accuracy and fillet thinning of alloy steel rim, a three-dimensional model of three pass rolling process was established, and the influence of different process parameters on forming quality was analyzed by using the finite element software, and the optimal process parameter combination was obtained. On this basis, the simulation results of wheel rim stress and strain for each pass rolling are analyzed, and the particle tracking technology is introduced to analyze the variation rule of stress in each incremental step. Finally, the simulation and experimental results show that the simulation thickness is basically consistent with the actual thickness, which improves the accuracy of rim rolling forming, and further verifies the correctness of rolling process simulation.

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Section: Rolling Processmentioning

confidence: 99%

Simulation Analysis and Optimization of Rolling Process of Steel Rim

Lv¹,

Mao²,

Li³

et al. 2021

WJM

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“…Rolling experiments of a single copper tube and diamond/ Cu composites were simulated by DEFORM-3D. The aim is to analyze rolling strain and temperature field in order to optimize the rolling process [35].…”

Section: Fem Simulationmentioning

confidence: 99%

Experiment and Simulation for Rolling of Diamond–Cu Composites

Wang

et al. 2017

Acta Metall. Sin. (Engl. Lett.)

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We demonstrate an innovative preparation approach of diamond/Cu composites by powder-in-tube technique and rolling. A small copper tube was loaded with Ti-and Cu-coated diamond particles, and then the diamond particles were combined with Cu matrix by composite rolling. The morphology and element distribution of the interface between diamond and Cu were determined by scanning electron microscopy and energy-dispersive spectrometer. Finite element method (FEM) simulation was used to analyze the rolling process associated with experiment by DEFORM-3D. The final experimental results showed that homogeneous distribution of diamond particles could be observed in the center layer of the composites. According to the contrast experiments, the sample, whose diamond particle size is 0.12-0.15 mm and thickness of pre-rolling is 1.2 mm, showed relatively complete morphologies and homogeneous distribution. Experimental results indicated a poor efficacy of excessive rolling reduction. The thermal conductivity of the composites is about 453 W (m K)-1 by theoretical calculation. For FEM simulation, rolling strain and temperature field of the composites were simulated by DEFORM-3D. Simulation results were interpreted, and numerical results verified the reliability of the model. The simulation predicted that the local area of large strain, indicative of the strain along the thickness direction, could be intensified by adding diamond particles.

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“…Actually, many defects occur during current manufacturing process, such as local excessive thinning or cracking and poor surface quality with scratches and abrasions [ 14 , 15 , 16 ]. Steels with 800 MPa ultimate tensile strength have been tried for the manufacture of wheels, yet steel with 600 MPa UTS is the preferred material for rim application [ 17 , 18 ]. Meanwhile, the rim directly bears the most force from the automobile body, and the forming quality of the rim directly affects the service performance of the wheel [ 19 , 20 ].…”

Section: Introductionmentioning

confidence: 99%

A Novel Hydroforming Process by Combining Internal and External Pressures for High-Strength Steel Wheel Rims

Chen

Song

et al. 2022

Materials

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As one of the key safety components in motor vehicles, the steel wheel rim is commonly fabricated with the roll forming process. However, due to the varied cross-sections of the rim and the low formability of high-strength steel, it is difficult to produce thin-wall and defect-free wheel rims to realize the purpose of light weight. To solve these problems, a novel hydroforming process by combining internal and external pressures (HIEP) was proposed to produce thin-wall wheel rims in the current study. The designed initial tube with diameter between the maximum and minimum diameter of the wheel rim ensures dispersed deformation and effectively avoids local excessive thinning. During HIEP, a hydroforming process was performed with two successive stages: the external pressure and internal pressure stages. Theoretical analysis and finite element method (FEM) were jointly used to investigate the effect of process parameters on the wrinkling and thinning. With the optimized parameters for internal and external pressure, the wrinkling of wheel rims is prevented under compressive state during the external pressure forming stage. Additionally, HIEP was experimentally carried out with high-strength steel rims of 650 MPa ultimate tensile strength (UTS). Finally, wheel rims with weight reduction of 13% were produced successfully, which shows a uniform thickness distribution with a local maximum thinning ratio of 11.4%.

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Finite element simulation and experiment verification of rolling forming for the truck wheel rim

Cited by 10 publications

References 17 publications

Simulation Analysis and Optimization of Rolling Process of Steel Rim

Simulation Analysis and Optimization of Rolling Process of Steel Rim

Experiment and Simulation for Rolling of Diamond–Cu Composites

A Novel Hydroforming Process by Combining Internal and External Pressures for High-Strength Steel Wheel Rims

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