Structural and process parameter optimization for rotary riveting of wheel hub bearing face teeth

The face teeth of wheel hub bearing are manufactured using a two-step rotary riveting forming process. Controlling the forming force and improving the tooth profile fullness are critical, as these factors directly affect bearing performance. This study employs DEFORM finite element simulation combined with experimental verification to analyze the influence of structural and process parameters – including blank dimensions, pre-riveting state, feed rate, spindle rotation speed, and riveting inclination angle – on the forming force and tooth profile fullness. Optimal structural and process parameters are thereby determined. The results indicate that among blank structural parameters, wall thickness has the greatest impact on tooth profile fullness, followed by inner corner radius, with outer corner radius having the least effect. Optimized blank dimensions improve profile fullness and reduce forming force. The pre-riveting state significantly influences the tooth forming process, a fully riveted state reduces axial forming force by 24.9 % compared to a non-riveted state and markedly improves profile fullness. A smaller feed rate and higher spindle speed reduce forming force and improve profile fullness, but may cause flash at the tooth outer edge. Conversely, excessive feed rate and low spindle speed reduce profile fullness. Experimental verification shows that optimized process parameters increase tooth profile fullness by 4.6 % to 96.2 % and reduce forming force by 17.8 % compared to pre-optimization conditions, confirming the effectiveness of the parameter optimization.