Die Design Parameter Optimization for Steering Intermediate Tube Using Taguchi Method

The increasing demand for lower cost and higher reliability of product of Indian OEM’s, one of the approach is using cheaper raw material considering design for X. In current steering intermediate tube, the development of replacing the imported material of STKM11A by local material of same grade has been done. The microstructure comparison shows there is variation in grain size and Mechanical properties of local and imported material and thus affects the formability of material. Increasing in mechanical properties such as hardness and tensile strength of material leads to challenge in actual forming as it affects the die life and its performance. In this paper, Non-linear explicit Axial cold forming process of Intermediate tube has been simulated through Finite Element Analysis Tool for both the local and imported material with optimization of die parameters. Dimensional requirement was one of the important parameter to correlate between the Design and Forming simulation. The parameter identified by past experience were Rough die opening angle, Mandrel forming angle, co-efficient of friction, Lobe width and Angle. Through Taguchi method, effect of each die parameter were done to study dimensional consistency, reaction force, residual stress and spring back effect. CAE analysis of tube forming performed was matching with actual forming with the difference of 0.22% for lobe width and 0.45% for lobe angle. Local material can be used for spline tube with die life reduction of 12% w.r.t imported material.