Compression forces in ball-joints assembled by edge-form rolling Druckkräfte in durch Kantenwalzen montierten Kugelgelenken K. T. Gürsel 1 , S. Çakır 2 Suspension ball-races, which are important elements of steering and suspension systems in vehicles, are manufactured by applying plastic forming technique to as- semble the parts after their spherical bearings are designed. In this study, the edge- form rolling process, which is a subsection of the rolling process in manufacturing methods based on plastic forming and used in the manufacturing of the suspension ball-races supplying the motion transmission, was examined comprehensively. The rates and magnitudes of pressure forces occurring in bearing systems after edge-form rolling processes were studied by changing operation pressures of this forming technique in which specific numerical simulations based on finite element analyses with implicit method were used. The results obtained from the developed edge-form rolling simulations were confirmed by the results of the test method devel- oped in this research. Keywords: Plastic forming / edge-form rolling / compression forces / suspension ball-race / ball-joint Schlüsselwörter: Plastische Formung / Kantenwalzen / Druckkräfte / Suspension-Kugelgelenkelement / Kugelgelenk 1 Introduction 1.1 Aim of the study When manufacturing of parts used in the automotive industry is analyzed in terms of cost and quality; it can be seen that feasibility studies prior to manufac- turing, manufacturing methods and strength proper- ties to be acquired by parts following the manufac- turing course influence the whole manufacturing process and are the basic parameters to be consid- ered not apart from each other. It is very important that these parameters should be selected compatibly with each other. Steering and suspension systems generally used in motor vehicles provide the safety of vehicle driving. Perfect functioning of the mechanisms of these sys- tems depends upon many spherical bearing elements with different functions (ball-joints) which are con- tained in the mechanisms. The spherical bearing ele- ments are assembled – even a little tightly – without gaps between, and mounted at respective systems. On the other hand, the extreme mounting in ball- joints causes high torque values, and thus extra per- formances, and very low tightening causes space in joint; both of which are undesirable cases. Design of a spherical bearing element providing long life, low- friction and desired operating points in all road con- Corresponding author: K. Turgut Gürsel, Dokuz Eylül University, Institute of Marine Sciences and Technol- ogy, Baku B. 100 Inciralti, 35340 Izmir, Turkey, E-Mail: turgut.gursel@deu.edu.tr 1 Dokuz Eylül University, Institute of Marine Sciences and Technology, Baku B. 100 Inciralti, 35340 Izmir, Turkey 2 Standard Profile, Finite Element Analysis Department OSB Sakarya Cad. No: 7, 45030 Manisa, Turkey Mat.-wiss. u. Werkstofftech. 2016,1–11 DOI 10.1002/mawe.201600338 © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.wiley-vch.de/home/muw 1