Abstract: Motorhomes steering knuckles had big dimensions and complicated structures. The split manufacturing technology currently used possessed the problems of low material utilization, low production efficiency, and poor product performance. So an integral die forging was proposed, and the optimization of the processes and the development of special facilities for the bending processes were focused on. With adopting classical plastic forming theory, finite element numerical simulations and physical tests, the stress-strain states, metal flows and damage distributions of the bending processes were analyzed. The results of the processing tests show that the proposed program is reasonable and that the integral die forging may be used instead of split manufacturing.The material utilization rate is increased from 45% to more than 70%, and the production efficiency is improved by 4 to 5 times.

Key words: motorhome steering knuckle, integral die forging, bending forming, die facility

摘要： 房车转向节轮廊尺寸大、结构极其复杂,目前采用的分体制造技术存在材料利用率和生产效率低、产品性能差的问题。为此,提出了转向节整体模锻成形的工艺方案,着重研究了其关键工序弯曲成形的工艺优化并进行了专用模具装置开发。采用经典塑性成形理论、有限元数值模拟和试验相结合的方法,分析了弯曲过程的应力应变状态、金属流动和损伤分布。工艺试验结果表明,所提出方案合理,实现了以整体模锻取代分体制造,材料利用率由约45%提高至70%以上,生产效率提高4~5倍。

关键词: 房车转向节, 整体模锻, 弯曲成形, 模具装置