Application of the finite-element method in the reform of light-weight vehicle construction

Abstract 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 parameters, five kinds of die scheme are studied. The factors resulting in a folding defect in the forging are analyzed and the means of eliminating the folding defect are put forward. The die design improved by FEM-based simulation can avoid the folding defect in the forging. The simulation results are also consistent with the forging practice of the Tokai Drop-Forging Co. Ltd., of Japan.