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To conduct an in-depth analysis of the wheel rim forming processes and effectively control rim forming quality defects, three-dimensional elastic–plastic finite element models of flaring and three rolling processes for 22.5 × 9.0-type steel wheel rim were established using ABAQUS software. Some key techniques in establishing models were investigated, such as methods of imposing boundary condition given by side guide wheels and enforcing load curve. The accuracy of the models was verified by comparing the simulation results with the point-cloud model of the actual produced rim in terms of exterior shape and thickness. Distributions and changes in the equivalent stress and equivalent plastic strain were analysed. The results indicate that the rim misalignment defect often occurs when the unequal width of the reserved material at the two ends of the rim is in the first rolling process. An improved die design is proposed. The results of the finite element analysis indicate that the improved dies are conducive to the flow of the material between the gap of the upper roller and the lower roller, and the difference in the rim width is significantly reduced

Finite element analysis on multi-step rolling process and controlling quality defect for steel wheel rim