A process-sequence design of an axle-housing by cold extrusion using thick-walled pipe

Abstract

This study is concerned with the method of production of an axle housing that covers an axle shaft with differential gears. The process sequence of the current five-stage cold extrusion process is investigated for the purpose of improving the sequence design. The new process has distinct advantages over the conventional process. It has a reduced process-sequence without buckling of the workpiece or overloading of tools. Also, it permits an optimal press selection to reduce the equipment cost. Based on the results of simulation of the current five-stage process, design strategy for improving the process-sequence is developed using the thick-walled pipe. The finished product of an axle housing is produced in two operations with one annealing treatment, whilst the conventional sequence consists of five operations with one treatment. Numerical results show that the newly-proposed process with selected presses is the most economical way to produce the required part.