Preform optimization of pad section of front axle beam using DEFORM

Die design optimization with computer simulation has certain advantages compared to the conventional methods performing by experience and trial and error. Metal forming simulation software has been used for process optimization of forge components. Utilization of such tools reduces iterative and time consuming approach by minimizing the billet mass and other design parameters. A commercially available software DEFORM is used for the purpose of finite element method simulation of front axle beam forging. Initially the die design of front axle beam has been done with the help of conventional method. Here 3D models of dies and preform shapes are prepared and exported to DEFORM software for simulation. The simulation trials entail the modifications in die design and preform shape. This paper describes the selection of optimum billet size for pad section of the front axle beam.