APPLICATION OF THE FINITE-ELEMENT METHOD IN THE REFORM OF LIGHTWEIGHTVEHICLE CONSTRUCTION

In this paper, the forging process of an aluminum alloy rear lower arm of the HONDA sports car NSX is simulated using the rigid-viscoplastic finite-element method (FEM). Through changing the die geometry parame ters, five kinds of die scheme are studied. The factors resulting in a folding defect in the forging are analyzed and the means of eliminati ng the folding defect are put forward. The die design improved by FEM- based simulation can avoid the folding defect in the forging. The simu lation results are also consistent with the forging practice of the To kai Drop-Forging Co. Ltd., of Japan.