Forming Analysis of an Inner Tie-Rod End Stud Using Finite Element Modeling and Experiments

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This study presents the finite element modeling of the forming process of an inner tie-rod end stud, complemented by experimental tests. Three rod-end stud designs made from two materials, SAE 1040 and 16MnCr5, were analyzed using both numerical and experimental methods. A nonlinear, displacement-based modeling technique is employed to simulate the stud closing operation, incorporating the material's multilinear isotropic hardening behavior. This study examines the effects of expansion during the forming of a tie-rod end stud in three different designs, with a focus on residual stresses and their impact on material behavior. Residual plastic strains are identified as a key factor contributing to material expansion in the wrench sections.The material hardening rate, reduced ductility after loading, and yield strength are also important parameters affecting the results. The hardness increases due to strain hardening for both 16MnCr5 and SAE 1040 steels, while the microstructure does not seem to have a notable influence on material expansion. The results indicate that no material expansion is observed in 16MnCr5 due to its higher yield strength and limited residual plastic strains in the critical wrench zone, in contrast to SAE 1040 steel. In comparison with the conventional inner tie-rod end stud, the wrench-flat length has a significant effect on material expansion due to the residual stresses concentrated at the sharp corners. Permanent damage at the formed end zone is observed in SAE 1040 steels due to its higher hardening rate and reduced ductility after forming.