scholarly journals A New Method of Manufacturing Hollow Shafts via Flexible Skew Rolling

2021 ◽  
Vol 2101 (1) ◽  
pp. 012010
Author(s):  
Xiaoqing Cao ◽  
Baoyu Wang ◽  
Wei Guo ◽  
Zhidong Ju
Keyword(s):  
Rolling Force ◽  
Rolling Process ◽  
Fe Model ◽  
Forming Process ◽  
Hollow Shaft ◽  
Process Adjustment ◽  
Rolling Load ◽  
Rolling Torque ◽  
Skew Rolling ◽  
Hollow Shafts

Abstract The existing rolling process of large and long axle parts, such as the cross wedge rolling (CWR) process, requires special molds and larger equipment. Flexible skew rolling (FSR) hollow shafts with mandrel is a near net-shape rolling technology which can achieve the diversified production of rolled parts without special molds. It has significant advantages such as small equipment tonnage, small die size, low rolling load, simple process adjustment, and especially suitable for multi-variety and small-batch production. This paper proposes hollow train shafts formed by FSR with mandrel. Reasonable parameters were selected for experiments, and the forming process was calculated by finite element (FE) software. The experimental results are consistent with the simulation results, indicating that the FE model is reliable. The rolling force and rolling torque are analyzed by simulation. Finally, the microstructure of different positions of the rolled-piece is analyzed, and the microstructure of the rolled part is refined. It is provide a feasible scheme for the rolling of large hollow shaft parts.

scholarly journals Numerical Analysis of a Skew Rolling Process for Producing a Stepped Hollow Shaft Made of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 61 (2) ◽  
pp. 677-682 ◽  
Author(s):  
Z. Pater ◽  
T. Bulzak ◽  
J. Tomczak
Keyword(s):  
Numerical Analysis ◽  
Thickness Distribution ◽  
Effective Strain ◽  
Rolling Process ◽  
Forming Process ◽  
Hollow Shaft ◽  
Wall Thickness Distribution ◽  
Light Trucks ◽  
Titanium Alloy Ti6al4v ◽  
Skew Rolling

Abstract The paper describes a rolling process for a hollow Ti6Al4V alloy shaft used in driving systems of light trucks. The shaft is formed by skew rolling using three tapered rolls. The principle of this forming process was discussed stressing its universality due to the potential of applying it for forming various products by one set of rolls. The numerical analysis results (product shape progression in rolling, wall thickness distribution, effective strain, temperature and variations in loads and torques) confirm that the proposed technique can be used for producing hollow long shafts.

Study on Load of Hollow Motor Shaft by 4-Roll Cross Wedge Rolling

2013 ◽  
Vol 288 ◽  
pp. 267-270 ◽  
Author(s):  
Yong Ming Yang ◽  
Feng Wen Cheng ◽  
Jiu Chuan Chen ◽  
Jun Zhao
Keyword(s):  
Rolling Force ◽  
Rolling Process ◽  
Fe Model ◽  
Motor Shaft ◽  
Cross Wedge Rolling ◽  
Mill Equipment ◽  
Die Structure ◽  
Forming Analysis ◽  
Rolling Load ◽  
Deform 3D

Rolling force is the main parameters for calculating the intensity and rigidity of the main parts in the mill. To determine the force produced by the four roll rolling process, the finite element (FE) model for hollow motor shaft forming using 4-roll cross wedge rolling had been established for forming analysis with the aid of FE software Deform-3D. According to the results of FE simulation, the rolling load rules were obtained and maximum force of up to 60 KN. It has important theoretical significance and application value for the mill equipment designing and die structure optimization.

3D FE Modeling of Three Rolls Cross Rolling Process of a Rotary Disk Part

2011 ◽  
Vol 189-193 ◽  
pp. 1991-1996 ◽  
Author(s):  
Xiu Mei Zhou ◽  
Lin Hua ◽  
Dong Sheng Qian
Keyword(s):  
Rolling Force ◽  
Rolling Process ◽  
Fe Model ◽  
Forming Process ◽  
Software Environment ◽  
Cross Rolling ◽  
Rolling Technique ◽  
Rotary Disk ◽  
Rotary Parts ◽  
Plastic Forming

Special rolling is also called rotary forming process, which is an advanced manufacture technology of making workpiece generate deformation in a rotary state by continuous local plastic forming. Disk rotary parts with outer stepped cross-section, such as wheels, flanges, valves and so on, are widely used in engineering machinery. Traditionally, this kind of part is manufactured by forging and cutting, which consumes a lot of energy and materials especially to the large size part. In this paper, a new specific rolling technique called three rolls cross rolling is first presented to produce this kind of part, and the principle and characteristics of this technique are described in detail. Then, base on the principle of the three rolls cross rolling, a 3D coupled thermo-mechanical FE model is developed under ABAQUS software environment. As a result, under the simulation and analyses of a real example, the feasibility of this technique is verified, and the evolutional laws of the strain, temperature and rolling force and power parameters during the process are investigated as well. The obtained results provide valuable guidelines for the further investigation on the forming characteristic of the three rolls cross rolling technique.

scholarly journals The Effect of Process Parameters in Helical Rolling of Balls on the Quality of Products and the Forming Process

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2125 ◽  
Author(s):  
Janusz Tomczak ◽  
Zbigniew Pater ◽  
Tomasz Bulzak
Keyword(s):  
Metal Flow ◽  
Experimental Tests ◽  
Rolling Process ◽  
Helical Rolling ◽  
Forming Process ◽  
University Of Technology ◽  
Quality Of Products ◽  
Skew Rolling

This paper presents selected numerical and experimental results of a skew rolling process for producing balls using helical tools. The study investigates the effect of the billet’s initial temperature on the quality of produced balls and the rolling process itself. In addition, the effect of billet diameter on the quality of produced balls is investigated. Experimental tests were performed using a helical rolling mill available at the Lublin University of Technology. The experiments consisted of rolling 40 mm diameter balls with the use of two helical tools. To determine optimal rolling parameters ensuring the highest quality of produced balls, numerical modelling was performed using the finite element method in the Forge software. The numerical analysis involved the determination of metal flow kinematics, temperature and damage criterion distributions, as well as the measurement of variations in the force parameters. The results demonstrate that the highest quality balls are produced from billet preheated to approximately 1000 °C.

Coupled Thermo-Mechanical FEA of Three-Roll Cross Rolling Process for Rings with Small-Hole and Deep Groove

2012 ◽  
Vol 560-561 ◽  
pp. 846-852 ◽  
Author(s):  
Qi Ma ◽  
Lin Hua ◽  
Dong Sheng Qian
Keyword(s):  
Rolling Process ◽  
Small Hole ◽  
Fe Model ◽  
Forming Process ◽  
Software Environment ◽  
Cross Rolling ◽  
Design And Optimization ◽  
Forming Technology ◽  
Deep Groove ◽  
Plastic Forming

Ring parts with small-hole and deep groove such as duplicate gear and double-side flange, are widely used in various engineering machineries. Three-roll cross rolling (TRCR) is a new advanced plastic forming technology for the processing of rings with small-hole and deep groove. In this paper, a 3D coupled thermo-mechanical FE model for TRCR of ring with small-hole and deep groove is established under ABAQUS software environment. By simulation and analysis, the evolution and distribution laws of strain and temperature in the forming process are revealed, and the effects of the key process parameters on the deformation uniformity are explored. The results provide valuable guideline for the technological parameter design and optimization.

FEM Simulation Analysis of Cross Wedge Rolling Process

2011 ◽  
Vol 381 ◽  
pp. 72-75
Author(s):  
Bin Li
Keyword(s):  
Simulation Analysis ◽  
Three Dimensional ◽  
Fem Simulation ◽  
Rolling Process ◽  
Stress Distributions ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Pressure Distributions ◽  
Metal Forming Process ◽  
Rolling Load

This paper investigates the interfacial slip between the forming tool and workpiece in a relatively new metal forming process, cross-wedge rolling. Based on the finite elements method, three-dimensional mechanical model of cross wedge rolling process has been developed. Examples of numerical simulation for strain, stress distributions and rolling load components have been included. The main advantages of the finite element method are: the capability of obtaining detailed solutions of the mechanics in a deforming body, namely, stresses, shapes, strains or contact pressure distributions; and the computer codes, can be used for a large variety of problems by simply changing the input data.

scholarly journals New Numerical Solution of von Karman Equation of Lengthwise Rolling

2015 ◽  
Vol 2015 ◽  
pp. 1-20 ◽  
Author(s):  
Rudolf Pernis ◽  
Tibor Kvackaj
Keyword(s):  
Contact Stress ◽  
Rolling Force ◽  
Rolling Process ◽  
Normal Contact Stress ◽  
Normal Contact ◽  
Circular Arch ◽  
Relative Stress ◽  
Roll Flattening ◽  
Polygonal Curve ◽  
Rolling Torque

The calculation of average material contact pressure to rolls base on mathematical theory of rolling process given by Karman equation was solved by many authors. The solutions reported by authors are used simplifications for solution of Karman equation. The simplifications are based on two cases for approximation of the circular arch: (a) by polygonal curve and (b) by parabola. The contribution of the present paper for solution of two-dimensional differential equation of rolling is based on description of the circular arch by equation of a circle. The new term relative stress as nondimensional variable was defined. The result from derived mathematical models can be calculated following variables: normal contact stress distribution, front and back tensions, angle of neutral point, coefficient of the arm of rolling force, rolling force, and rolling torque during rolling process. Laboratory cold rolled experiment of CuZn30 brass material was performed. Work hardening during brass processing was calculated. Comparison of theoretical values of normal contact stress with values of normal contact stress obtained from cold rolling experiment was performed. The calculations were not concluded with roll flattening.

scholarly journals Forming of Hollow Shaft Forging From Titanium Alloy Ti6Al4V by Means of Rotary Compression

2015 ◽  
Vol 60 (1) ◽  
pp. 419-425 ◽  
Author(s):  
J. Tomczak ◽  
Z. Pater ◽  
T. Bulzak
Keyword(s):  
Titanium Alloys ◽  
Automotive Industry ◽  
Experimental Tests ◽  
Aviation Industry ◽  
Forming Process ◽  
Compression Process ◽  
Hollow Shaft ◽  
Experimental Works ◽  
Titanium Alloy Ti6al4v ◽  
Hollow Shafts

Abstract This paper presents chosen results of theoretical-experimental works concerning forming of hollow shafts forgings from titanium alloys, which are applied in aviation industry. At the first stage of conducted analysis, the forging forming process was modeled by means of finite element method. Calculations were made using software Simufact Forming. On the basis of performed simulations optimal parameters of rotary compression process were determined. Next, experimental tests of forging forming in laboratory conditions were made. For the research needs, a forging aggregate, designed by the Authors, was used. Conducted research works confirmed the possibility of metal forming (by means of rotary compression) of hollow shafts from hard workable titanium alloys. Numerous advantages of rotary compression process, make it attractive both for low series production (aircraft industry) and for mass production (automotive industry).

Numerical Simulation of GH4169 Alloy Section of Hot Roll Forming

2014 ◽  
Vol 904 ◽  
pp. 479-482
Author(s):  
Lei Gao ◽  
Yu Hua Pang ◽  
Lie Sun ◽  
Da Rong Tian
Keyword(s):  
Surface Temperature ◽  
Rolling Force ◽  
Effective Strain ◽  
Rolling Process ◽  
Roll Forming ◽  
Structure Property ◽  
Forming Process ◽  
Rigid Plastic ◽  
Roll Forming Process ◽  
Gh4169 Alloy

A hot roll forming process of GH4169 alloy complex sections described in this paper is a new forming process of GH4169 alloy sections. The rolling 6o, 7o, 8o pass and rectangular, wedge-shaped, irregular blank are designed. Rolling models has been developed using the rigid-plastic finite element method on DEFORM. The rolling force and pass fullness and the distribution of various field-variables such as temperature and effective strain can be obtained from the simulated result. The finally optimizing rolling process shows that the pass slopes with 6o on the roll, the cross-section of the blank is irregular, and the rolling processes are using one pass to do two passes rolling through changing the value of the roll gauge. The simulated results show the temperature of the workpiece is about 1030~1080°C, the inner temperature is greater than the surface temperature, the surface temperature is minimum, and the effective strain is about 0.3~2, which meet the requirement of the GH4169 alloy structure property, and they are significance to the other hot roll forming process of GH4169 alloy sections.

Application of a Material Model to Predict Rolling Forces and Microstructure during a Hot Ring Rolling Process

2013 ◽  
Vol 762 ◽  
pp. 354-359 ◽  
Author(s):  
Thomas Henke ◽  
Gerhard Hirt ◽  
Markus Bambach
Keyword(s):  
Grain Size ◽  
Microstructure Evolution ◽  
Rolling Force ◽  
Flow Behavior ◽  
Rolling Process ◽  
Ring Rolling ◽  
Experimental Investigations ◽  
Forming Process ◽  
Ring Geometry ◽  
Ring Rolling Process

Ring rolling is an incremental bulk forming process. Hence, the process consists of a large number of alternating deformations and dwell steps. For accurate calculations of material flow and thus ring geometry and rolling forces in hot ring rolling processes, it seems necessary to consider material softening due to static and post dynamic recrystallization which could occur between two deformation steps. In addition, due to the large number of cycles, the modeling results, especially the prediction of grain size, can easily be affected by uncertainties in the input data. However, for small rings and ring material with slow recrystallization kinetics, the interpass times can be short compared to the softening kinetics and the effect of softening can be so small, that microstructure evolution and the description of the materials flow behavior can be de-coupled. In this paper, a semi-empirical JMAK-based model for a stainless steel (1.4301/ X5CrNi18-9/ AISI304) is presented and evaluated by the use of experiments and other investigations published in [1],[2]. Finite Element (FE) simulations of a ring rolling process with a high number of ring revolutions and thus multiple, incremental forming steps were conducted based on ring rolling experiments. The FE simulation results were validated with the experimentally derived rolling force and evolution of ring diameter. The microstructure evolution was calculated in a post processing step considering the investigated evolution of strain and temperature. In this calculation the interrelations between the fraction of dynamically recrystallized microstructure, the evolution of post-dynamically recrystallized microstructure and the final grain size have been considered. Both, the calculated final microstructure and the evolution of rolling force and ring geometry calculated stand in good agreement with the experimental investigations.

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