Abstract: The precision roll forging-die forging for automo- bile front axle is a plastic working technology of large front axle forging by small rating forging press. The key of this tech-nology is precision roll forging. Roll forging process of front axel includes 4 steps，which is a class successive partial plastic forming. Due to the contact areas between dies and work piece varying in forming, the simulation for this process is very diffi- cult. The FEM (Finite element method) models for 4 process steps are modeled, and the rigid-plastic FEM program DEFO- RM-3D is used to simulation roll forging. Material deformation laws in roll forging are studied, and effects of die geometrical parameters and process design values on forming quality are investigated. Comparison between the computational results and tests results shows that the numerical simulation can predict perfectly the shapes and flaws of workpiece in rolling forging.

Key words: Automobile front axle, FEM, Numerical simulation, Roll forging