Finite Element Analysis Model of Rotary Forging for Assembling Wheel Hub Bearing Assembly

In this paper, a computationally efficient finite element analysis model of the rotary forging process for assembling a wheel hub bearing assembly is presented. The analysis model is composed of a part of material defined by two artificial planes of symmetry, which is to reduce computational time taken in simulating the holistic process. Three cases of 30°, 60° and 90° analysis models for simulating rotary forging processes are studied to validate the present finite element analysis model. The predictions at their planes of symmetry and mid-planes are investigated and compared with the experiments, revealing that the predictions at the mid-planes are in good agreement with the experiments for all the cases while those at the planes of symmetry are to the contrary. Thus, the 60° analysis model is recommended for both computational efficiency and solution reliability. With the present finite element analysis model, one hour of computational time with PC can be sufficient enough to obtain valuable information about such rotary forging processes as the wheel hub bearing assembly making process