Core application and technological evolution of aluminum alloy hot forgings in truck parts
Principles and core advantages of aluminum alloy hot forging technology
The hot forging process heats the aluminum alloy metal to above the recrystallization temperature (usually 60%-85% of the melting point of the material) and uses a mold to precisely shape the material in a plastic state. It is widely used in the manufacture of truck parts. Its technical advantages are reflected in:
1、High strength and fatigue resistance: The internal fibers of aluminum alloy hot f
orgings are continuous and the grains are refined, which can withstand impact loads of up to 200MPa in heavy-duty truck transportation;
2、Adaptability to complex geometric structures: Suitable for forming parts with three-dimensional curved surface features such as engine crankshafts and gearbox gears;
3、Material performance optimization: Eliminate casting defects through dynamic recrystallization and improve the stability of parts at extreme temperatures (-40℃ to 200℃).
Application of hot forgings in front-end truck components
As the key load-bearing area of trucks, front-end components rely on hot forging technology to achieve performance breakthroughs:
1、Steering knuckle: 42CrMo steel is hot forged, and the yield strength is increased by 30%, supporting the stable operation of the steering system of 16-ton heavy trucks ;
2、Suspension control arm: Through the closed die forging process, a single piece can be reduced by 15% while maintaining the same load-bearing capacity, effectively reducing fuel consumption ;
3、Hub unit: The high-carbon steel hot forged hub adopts a streamlined fiber distribution design, and the torsional stiffness reaches 1800N·m/rad, which can adapt to complex road conditions .
Hot forging parts of truck power and transmission systems
1、Engine core parts :
- Crankshaft: The integral die forging process is adopted to eliminate the stress concentration of traditional welded joints, and the fatigue life is increased by 2.5 times ;
- Connecting rod: Through the residual heat isothermal quenching technology, the tensile strength exceeds 1200MPa, meeting the requirements of the National VI emission engine .
2、Transmission gear set:
- Main reducer gear: 20CrMnTiH steel hot forging surface hardness reaches HRC58-62, tooth surface contact strength increased by 40%;
- Transmission shaft universal joint: Multi-directional die forging process realizes the integral forming of the cross shaft, and the torque transmission efficiency reaches 98.5%.
、 hot forging technology innovation and industry trends
1、Application of lightweight materials:
- Titanium alloy steering knuckle (Ti-6Al-4V) achieves 30% weight reduction, which has been verified in high-end heavy truck test assembly;
- Aluminum alloy transmission parts (7075-T6) hot forging process breakthrough, yield strength reaches 500MPa.
2、Intelligent manufacturing upgrade:
- Based on digital twin aluminum alloy hot forging process simulation system, the mold development cycle is shortened by 60%;
- Intelligent temperature control forging line (±10℃ accuracy) achieves stable production of 500,000 pieces per year.
3、Composite process integration:
- 3D printing preforming + aluminum alloy hot forging precision forging technology to produce turbocharger impellers with internal cooling channels;
- Laser surface strengthening and hot forging collaborative process, gear surface wear resistance increased by 3 times.
. Typical application case analysis
1、Scania heavy-duty tractor:
- The whole vehicle uses 68 aluminum alloy hot forging key parts, among which the front axle steering knuckle achieves a maintenance-free design of 2 million kilometers;
- The hot forged V8 engine crankshaft has a single load-bearing capacity of 8 tons and supports a power output of 750 horsepower.
2、SINOTRUK HOWO-A7 series:
- Hot forged aluminum alloy wheel hub components reduce the weight of the whole vehicle by 120kg and reduce fuel consumption by 1.2L per 100 kilometers;
- The intelligent forging production line achieves a monthly production of 20,000 sets of gearbox gear sets with an accuracy error of ≤0.05mm.
Hot forgings have formed a complete application system from front-end components to powertrain in truck manufacturing. Through material innovation (titanium alloy/aluminum alloy), process upgrade (intelligent temperature control/composite manufacturing) and system integration (digital twin/automated production line), the industry continues to develop in the direction of high strength, lightweight and long life. In the future, with the expansion of the new energy heavy truck market, hot forging technology will open up new application space in the field of electric drive system components.
Application case of hot forgings in trucks: heavy truck axle manufacturing
1. Case background
Heavy truck axles are the core components of vehicle power transmission and load-bearing. Their performance directly affects the load capacity, stability and service life of the truck. The traditional axle manufacturing process has problems such as low material utilization and long processing cycle, while the introduction of hot forging technology has significantly improved the performance and production efficiency of the axle.
2. Application of hot forging technology in axle manufacturing
1、Material selection: 42CrMo alloy steel is used, and its yield strength after hot forging can reach 900MPa, and its fatigue resistance is improved by 40%, which meets the high-load working conditions of heavy trucks.
2、Forming process:
- Through the closed die forging process, the axle tube and flange are integrated, the welding joints are reduced, and the risk of stress concentration is reduced;
- The intelligent temperature control system (±10℃ accuracy) is used to ensure the uniformity of material organization during hot forging and avoid internal defects.
3、Performance optimization:
- The internal fibers of the hot forging are continuously distributed, and the torsional stiffness is increased by 35%, which meets the high torque transmission requirements under complex road conditions;
- The surface is laser strengthened, the wear resistance is increased by 3 times, and the service life of the axle is extended.
- 3. Practical application effect
1.Performance improvement:
~The load-bearing capacity of the axle is increased from 16 tons to 20 tons, meeting higher load requirements ;
~The fatigue life exceeds 1 million kilometers, significantly reducing maintenance costs .
2.Economic benefits:
~The material utilization rate is increased from 65% to 85%, and the unit cost is reduced by 15% ;
~The production cycle is shortened by 30%, and the annual production capacity is increased to 100,000 sets . - 4. Future development direction
1.Lightweight design: Introducing titanium alloy (Ti-6Al-4V) hot forging process to achieve 25% weight reduction of the axle and further reduce fuel consumption ;
2.Intelligent production: Combined with aluminum alloy hot forging technology, the full process simulation optimization of the hot forging process is realized to improve product consistency and reliability .
The application of hot forging technology in the manufacturing of heavy truck axles not only significantly improves the performance and reliability of the products, but also achieves cost reduction and efficiency improvement through process optimization. In the future, with the introduction of new materials and intelligent technologies, the application of aluminum alloy hot forgings in truck manufacturing will be more extensive and in-depth .
