Application of FE analysis for optimal design of caulking process

An inner tie-rod (ITR) end-assembly module is widely used in the steering systems of automobiles. The ITR module is composed of a ball-stud, ball-seat, and socket and manufactured by a caulking process. To ensure that the final ITR module is qualified for application, the caulking process of the ITR module should be optimized to satisfy certain requirements, including the allowable displacement, pull-out force, tilting angle, and torque of the ball-stud. Accordingly, this paper investigates the deformation characteristics of both the caulking and pull-out processes using an FE analysis and clarifies the effect of the forming parameters on the allowable displacement, pull-out force, and tilting angle. The FE analysis results are also compared with experiments to validate the FE analysis.