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"Automobiles Axles."
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Thermal Analysis of Automobile Drive Axles by the Thermal Network Method
Excessive temperature is detrimental to the operation stability of the automobile drive axle. It is necessary to judge whether the highest temperature exceeds the limited dangerous temperature and study the effects of key factors on reducing the temperature. In this study, the temperature field distribution (TFD) of the automobile drive axle is revealed using the thermal network method (TNM). Compared with the experimentation and finite element analysis (FEA), the TNM is more convenient for obtaining the temperature. Subsequently, the highest temperature of the automobile drive axle is clear and applied to judge whether the highest temperature exceeds the limited dangerous temperature. On the basis of the TNM, the structure and parameter effects of the automobile drive axle on reducing the temperature are studied, which improves the operation stability and working life. Several conclusions can be drawn. The highest temperatures of two-axle and planetary automobile drive axles are both located in the motor. Compared with the two-axle drive axle, the highest temperature of the planetary drive axle is obviously lower. Therefore, in terms of the planetary drive axle, the possibility of exceeding the limited dangerous temperature is lower. In addition, on the premise of ensuring the normal operation, the motor output power, the friction coefficient among teeth, the helical angle of the gear, and the thermal transfer coefficient of the lubricating oil can be optimized to be lower for reducing the temperature of the automobile drive axle.
Journal Article
Influence of Graded Surface Decarburization of Automobile Forging Front Axle on the Bending Behavior Based on a Third-Order Shear Deformation Beam Theory
During the forging process of automobile front axle, the steel near the surface is often decarburized for a certain depth. The mechanical properties at the decarburization layer are graded and different from the inner area, influencing the bending behavior of axles under heavy loads. In this paper, the decarburized forging of front axle is regarded as a rectangular thick sandwich beam, composed of a homogeneous core and the functionally graded layer coated on both bottom and top surface. A Third-order Shear Deformation Theory (TSDT) is employed to investigate the static bending behaviors under two point−loads. The properties of sandwich FG material are represented with a piecewise power−law function, and the displacement field governing equations are derived through the virtual work principle. The Navier analytical method and numerical DQM procedures are employed to obtain the bending responses under simply supported boundary conditions, and the results are validated through the comparison with an example in the literature. Then, the transverse deflection, rotation, axial stress, and shear stress are studied in terms of different power−law exponents, decarburization depth, unsymmetrical decarburization depth, unbalance loading, and beam sectional dimension. The study reveals the influence of surface decarburization on the bending behavior of forged automobile front axles, and contributes to the optimization of structure design.
Journal Article
The influences of process parameters on the preliminary roll-forging process of the AISI-1045 automobile front axle beam
Roll-forging process is widely used to fabricate the automobile front axle beams. The reasonable selection of the process parameters is significant to ensure the quality and improve the property of the automobile front axle beam owing to the complexity and importance of the preliminary roll-forging process. This paper developed a 3D Finite element (FE) model of the preliminary roll-forging process of the AISI-1045 automobile front axle beam under the Deform-3D platform. A corresponding experiment is subsequently conducted. Good agreement between the experimental and simulative results validates the employed model. Based on this dependable FE model, the influences of initial temperature of billet
T
0
, rotational speed of rolls
n
and friction factor
m
on the geometric dimension, temperature inhomogeneity, deformation inhomogeneity, and roll-forging load are investigated comprehensively. The results can provide reliable guidelines for the selection of process parameters.
Journal Article
THE GRAPHICAL REPRESENTATION IN CATIA V5 OF AN AUTOMOTIVE TRANSMISSION
In the present paper is defined and presented the method of representation of an automotive transmission using CATIA V5 software, having as reference the Dacia Duster automobile. This paper contains the steps required for 3D modeling of transmission for a better understanding of functionality and the role fulfilled in the vehicle. Creating the virtual model for the car transmission allows us to emphasize the compatibility between elements and the subassemblies of the front and rear axle’s structure.
Journal Article
Study of Bulging-Pressing Compound-Deforming Automobile Axle Housing with a Common Press
The conventional hydroforming process for automobile axle housing needs a large-tonnage press and has the drawback of the dome part being apt to burst due to the large thinning. A new forming technology, bulging-pressing compound-deforming for automobile axle housing, is proposed, which is suitable for the large variable-diameter tube parts with special-shaped cross-sections. The initial tube is made into the axisymmetric peforming tube after the ends necked and the middle hydroformed, and which then is pressed into the axle housing sample by the dies. For a small automobile axle housing, the process tryout and the pressing dies were designed, and the axle housing samples were successfully produced with a common press. Compare with the conventional hydroforming process, the forming corner radiuses of present samples are smaller and the internal pressure decreased 60%. The results show that the process has the advantages of good corner-filling ability and low internal hydraulic pressure.
Journal Article
Based on 3D Virtual Prototype Technology and Finite Element Analysis of the Optimization of the Automobile Front Axle
The front axle is an important part of a car, directly affects the dynamic characteristics of car. Based on UG NX6.0 for automobile front axle parts 3D modeling, finite element analysis software ANSYS modal analysis was carried out on the front axle, and extract their first four order natural frequency and vibration mode shapes, the automobile front axle structure stress analysis and stress distribution nephogram of get parts. Analysis of the impact load condition and emergency braking conditions modal analysis, and further to fatigue analysis of the front axle bridge shell, for provide valuable reference data for the reasonable design of parts. For the kinetics of further research and improvement of front axle provides the theoretical basis, but also provides reference to the actual test.
Journal Article
New type of groove used to improve friction in roll forging
A FEM model for a failed industrial example of roll forging was established to analyze the generation mechanisms of the mismatch of size and shape of two spring board. To demonstrate the formulation of these defects, the bites condition and contact status between rectangular groove and workpiece during rolling the first and second spring boards were analyzed. Then, a new oval-diamond groove combining oval groove and diamond groove was presented to eliminate these defects. By analyzing field variables under the same deformation degree, the larger friction can be obtained on the contact surface of workpiece and the oval-diamond groove. The physical experiment validates that the oval-diamond groove can eliminate these defects effectively, and the size of part is in good agreement with design requirement.
Journal Article
Bending Analysis and Measures of the Forming of Automobile Semi-Axle on Cross-Wedge Rolling with Multi-Wedge
When forming automobile semi-axle using Multi-wedges Cross-Wedge Rolling (MCWR), it is difficult to avoid the rolling bending phenomenon. Thus to improve the product quality for finding out the causes and preventing rolling bending is essential. In this paper, the finite element model(FEM) analysis software Deform-3D was used to analize the bending causes, and giving the corresponding measures from numerical simulation of the forming of multi-wedge automobile semi-axle using Cross-Wedge Rolling. Based on the corresponding simulation experiments, the results indicate that the seasures is feasible. The results of this study for rolling forming of automobile semi-axle can improve product quality and provide a theoretical basis.
Journal Article
Roll Forging Technology and 3D Finite Element Simulation of Automobile Front Axle
According to the characters, technological condition and requirements of automotive front axle forging, the advantage of the roll forging and integral die forging complex process for automobile front axle were explained, including the determination of roll- forging parts chart, selection of billet dimension, decision of roll- forging steps, special roller- shaped design of typical section, and the front sliding parameter is calculated, its effect to length of forging parts gets analyzed. In this paper, taking NHR front axle as an instance, both the process of exact roll- forging billet and die design are studied, as the result, roll- forging die、 performing roll- forging die and final roll-forging die are design respectively. The process for roll forging was simulated by the three dimensional finite element analyses under isothermal condition, and metal flow procedure and force time curve were obtained. The connection among metal flow law and die cavity design and forming load were also analyzed. To verify the reliability of the simulation, the results for profile was compared with the tested forging part, showing that metal flow law of both are coincident and FE simulation of roll forging is accurate. Practice testify that FE simulation of roll forging for front axle can reduce the time of process design and procedure debugging and be helpful to response the market demand.
Journal Article