Effect of rolling parameters on forming quality of flat cross wedge rolling thread shafts

2020 ◽  
pp. 095440892095259 ◽  
Author(s):  
YiYu Shao ◽  
WenFei Peng ◽  
Xuan Yu ◽  
Moliar Oleksandr ◽  
Vyacheslav Titov
Keyword(s):  
Axial Force ◽  
Element Model ◽  
Helix Angle ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Forming Quality ◽  
Rolling Parameter ◽  
The Right ◽  
Forming Angle

The flat cross wedge rolling is an advanced forming process, which is used to produce thread shafts. In this work, a finite element model of flat cross wedge rolling thread shafts was established by the DEFORM-3D, and the effect of the forming angle, spreading angle, helix angle and flank angle on forming quality are investigated. The research results show that the forming angle, spreading angle, helix angle have a significant influence on the position of the die wedge-in point. The angle designed wrongly makes the die wedge-in point unable to be aligned correctly, causing defects such as slipping in the process, repeated rolling of formed thread, thin or incomplete tooth shapes. The flank angle mainly makes an impact on the axial force. Reducing the right flank angle or increasing the left flank angle can effectively improve the imbalance of axial force to obtain high-quality thread shafts. Through the experiment of flat cross wedge rolling thread shafts, the data comparison demonstrates that the error of the external dimension of formed parts is small, proving the reliability of the rolling parameter selection.

Study on the Regularity of the Center Quality of Cross Wedge Rolling Asymmetric Shaft Parts Based on Parity Wedge

2014 ◽  
Vol 488-489 ◽  
pp. 1125-1129
Author(s):  
Xue Dao Shu ◽  
Wen Ping Liu ◽  
Chao Cheng ◽  
Zhan Li ◽  
Wen Fei Peng ◽  
...  
Keyword(s):  
Systematic Study ◽  
Theoretical Foundation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Study Results ◽  
Technology Applications ◽  
Forming Angle ◽  
Core Part ◽  
Rolling Technology

In order to expand cross wedge rolling technology applications further and improving the quality of asymmetric shaft parts, this paper predicts the position of center defect location of Cross Wedge Rolling asymmetric shaft parts based on Parity Wedge by Normalized C & L criteria. On this basis, it conducted a systematic study on the effect of forming angle on quality of rolling core part. It has found that, during the forming process of Cross Wedge Rolling shaft parts, rolling center region was more prone to damage, and achieved the regularity of process parameters on the quality of core part. The study results lay the theoretical foundation for preventing defects effectively and improving quality of rolling core part.

Analysis of Square Billet Cross Wedge Rolling Process Using Finite Element Method

2012 ◽  
Vol 271-272 ◽  
pp. 406-411 ◽  
Author(s):  
Wen Yu Ma ◽  
Bao Yu Wang ◽  
Jing Zhou ◽  
Qiao Yun Li
Keyword(s):  
Finite Element ◽  
Rolling Force ◽  
Element Model ◽  
Rolling Process ◽  
Simulation Software ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Radial Forces ◽  
Forming Angle ◽  
Deform 3D

The aim of this paper is to determine whether the train axle cross wedge rolling(CWR) using square billet as blank is available or not. Based on numerical simulation software DEFORM-3D, we built the finite element model. And the whole forming process was simulated successfully. The stress and strain distributions of workpiece in the process were analyzed. The effect of forming angle, stretching angle and billet size on rolling force was investigated, then determined the proper process parameters. The differences between the round billet rolling and the square billet rolling were obtained by comparing the tangential, axial and radial forces during the rolling process. The studied results show the availability of using square billet as blank in train axle CWR and provide important realistic meaning and application value.

Effect of Thread Helix Angle on the Axial Metal Flow of Cross Wedge Rolling Thread Shaft

2013 ◽  
Vol 440 ◽  
pp. 177-181 ◽  
Author(s):  
Hua Jun Yan ◽  
Li Juan Wang ◽  
Yu Zhong Liu ◽  
Guo Chang Li ◽  
Jin Ping Liu ◽  
...  
Keyword(s):  
Rolling Force ◽  
Flow Direction ◽  
Metal Flow ◽  
Axial Flow ◽  
Helix Angle ◽  
Reverse Direction ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
3D Software

When rolling thread shaft in cross wedge rolling, forming quality of thread is affected by many process parameters such as the thread helix angle, which is a special and complex parameter. However, there is few study of the effect of the thread helix angle on thread shaft forming. In this paper how thread helix angle affects axial metal flow was analyzed from the perspective of rolling force and the forming process of thread shaft was simulated with different helix angles by the deform-3D software. Through the measurement of the point coordinates, the effect of the helix angle on the axial metal flow of rolled pieces was analyzed. Finally, the conclusion was obtained that helix angle causes the asymmetry of axial metal flow with small difference values for asymmetry and the axial metal flow of rolled pieces increases as the helix angle increases. The rolling thread segment can be ensured in the middle of rolled pieces by moving the blank a suitable distance in the reverse direction of the axial flow direction.

Theoretical Research of the Axial Force about Cross Wedge Rolling

2010 ◽  
Vol 443 ◽  
pp. 27-32 ◽  
Author(s):  
Wen Fei Peng ◽  
Kang Sheng Zhang
Keyword(s):  
Axial Force ◽  
Frictional Force ◽  
Energy Parameter ◽  
Theoretical Research ◽  
Cross Wedge Rolling ◽  
Projected Area ◽  
Forming Quality ◽  
Area Reduction ◽  
Contact Surfaces

Axial force in CWR is an important force and energy parameter for stable rolling, which plays an important role in studying the forming quality of asymmetric shaft-parts, section shrinkage of rolled parts and rolling of heavy area reduction. By simplifying boundary conditions of solving axial projected area in this paper, and considering the effects of frictional force generated by contact surfaces between the tools and shaped shaft-section, the formula of the axial force has been derived by analytical method; by comparison of axial force values simulated by ANSYS/LS-DYNA FE software and measured through experiment, the formula of the axial force is verified correctly. The analyzing results provide useful reference for solving process problems caused by axial force.

A Research on Steel Synchronizer Gear Ring's Precision Forging

2008 ◽  
Vol 575-578 ◽  
pp. 226-230 ◽  
Author(s):  
Song Xue ◽  
Jie Zhou
Keyword(s):  
Forming Process ◽  
Forming Quality ◽  
Precision Forging ◽  
Manufacturing Procedure ◽  
Gear Ring

Precision forging is an important manufacturing procedure of steel synchronizer gear ring forming. FEM software DEFORM_3D was applied to simulate the forming process and the problems in the forming process were been solved. The important factors those influence on precision forming of steel synchronizer gear ring are studied and the results are verified in practice. The results show that the size of billet, forging temperature, and thickness of web strongly influence the forming quality of steel synchronizer gear ring.

Research of New Splitting Process of Pipe Billets from 2618A Aluminium Alloy Basing on Cross-Wedge Rolling

2013 ◽  
Vol 58 (3) ◽  
pp. 725-729 ◽  
Author(s):  
A. Tofil
Keyword(s):  
Aluminium Alloy ◽  
Experimental Research ◽  
Cross Wedge Rolling ◽  
Bending Angle ◽  
Precise Analysis ◽  
Rolling Method ◽  
Material Separation ◽  
Forming Angle ◽  
Splitting Process

Abstract This paper are presented the results of theoretical and experimental research on splitting without waste of pipe billets from aluminium alloy realized basing on cross-wedge rolling method. The analyzed process is connected with rolling of a V-shape groove on a split billet circumference, and later with rotary bending causing material separation. In theoretical analysis, based on simulations by means of finite element method, basic models of metal cracking (brittle and ductile) were applied. During calculations, the following process parameters were changed: forming angle α, bending angle θ and reduction ratio ∆r. The achieved results allowed for a precise analysis of the splitting process within the scope of: state of strain, kinematics of flow, force parameters, state of stresses and type of cracking of the split material. On the basis of experimental research, the influence of the analyzed parameters on the surface of splitting was estimated and scope of parameters guaranteeing the assumed quality of the product was given. The comparison of theoretical and experimental results showed good conformity.

scholarly journals Optimization of Tooling Design for Hot Mandrel Bending of Pipe Elbows

2018 ◽  
Vol 918 ◽  
pp. 159-164 ◽  
Author(s):  
Uwe Diekmann ◽  
Werner Homberg ◽  
Jens Prehm ◽  
Tim Rostek ◽  
Nils Schönhoff ◽  
...  
Keyword(s):  
Numerical Simulations ◽  
Element Model ◽  
Resource Efficiency ◽  
Tool Geometry ◽  
Data Sets ◽  
Damage Models ◽  
Pipe Elbow ◽  
Tooling Design ◽  
The Right

This paper presents the finite element model developed for the simulation of pipe elbow production by the so-called ‘Hamburg process’ in order to improve productivity and resource efficiency. To optimize the tooling design, a sensitivity analysis of the tool parameters that influence the quality of pipe elbows, such as mandrel height and length, is conducted. Different materials data sets including damage models were considered. Using numerical simulations, it is possible to determine an optimized tool geometry for the production of specific pipe elbow dimensions. Furthermore, as a result of the experiments and numerical simulations conducted, it is possible to increase the production velocity of the serial plant. Along with deformation, damage models are included in simulations in order to identify the right process boundaries. Finally, an experimentally validated model is developed for increasing resource efficiency in pipe elbow fabrication.

Deformation Prediction of the Bipolar Plate Stamping

2014 ◽  
Vol 971-973 ◽  
pp. 270-274
Author(s):  
Hao Gao ◽  
Jian Lan ◽  
Lin Hua
Keyword(s):  
Fuel Cell ◽  
Proton Exchange Membrane ◽  
Bipolar Plate ◽  
Proton Exchange ◽  
Channel Number ◽  
Forming Process ◽  
Dimensional Error ◽  
The Right ◽  
Exchange Membrane

Bipolar plate is the key component of proton exchange membrane (PEM) fuel cell and represents a significant part of the overall cost and the total weight in a fuel cell stack. Many research have been done on the manufacturing methods of bipolar plate, among which stamping is very popular. With the increasing of the channel number and complexity, its dimensional error caused by sprinkback will change a lot, even under the same forming process. And the risk of crack is also different. These all impact the quality of bipolar plate. In order to predict deformation of channels and the plate’s quality, the displacement along X-axis, the strain and stress state, and the displacement along Z-axis are measured. The results show that 1) the risk of crack increases with the increasing of channel number; 2) the springbacks increase with the increasing of channel number; 3) the most dangerous point locates on the right internal fillet of the plate’s last section.

Research on Catalyst Penetration Process of Patternless Casting Manufacturing Technique

2014 ◽  
Vol 609-610 ◽  
pp. 1515-1520 ◽  
Author(s):  
Wei Dong Yang ◽  
Zhan Qun Shi ◽  
Li Li
Keyword(s):  
Rapid Prototyping ◽  
Surface Quality ◽  
Dimensional Accuracy ◽  
Single Droplet ◽  
Forming Process ◽  
Penetration Process ◽  
Forming Quality ◽  
Main Factors ◽  
Sand Particles

Pattenless Casting Manufacturing (PCM) technique is a kind of Rapid Prototyping based on droplet injection, using discrete nozzle to jet the catalyst. The quality of scanning lines has the most important effect on the sand strength, its surface quality and dimensional accuracy. The penetration and curing rules of the catalyst in the resined-sand particles are the main factors to determine the shape of the scanning lines. In order to study the penetration rules of the catalyst in the resined-sand, the penetration process of a single droplet and scanning lines are analyzed theoretically and verified by experiments. The important parameters of the forming process are determined based on the research and experimental results. It will provide the foundation to improve the forming quality of PCM technique.

Influence Regularities of Axial Force of Cross Wedge Rolling Symmetric Shaft-Parts about Technical Parameters

2011 ◽  
Vol 314-316 ◽  
pp. 589-593 ◽  
Author(s):  
Xue Dao Shu ◽  
Bao Shou Sun ◽  
Min Xiao
Keyword(s):  
Finite Element ◽  
Axial Force ◽  
Rolling Force ◽  
Element Model ◽  
Force Balance ◽  
Mold Design ◽  
Key Factors ◽  
Cross Wedge Rolling ◽  
Technical Parameters ◽  
Finite Element Software

Because of unbalanced axial force of cross wedge rolling asymmetric shaft-parts causing the rolling play and not stably, it is key factors to restrict application in asymmetric shaft-parts of cross wedge rolling. Axial force balance depends on technical parameters. So the influence regularities of axial force to technical parameters is researched in this paper by Ansys-Ls/Dyna finite element software. Finite element model is authenticated by experiment of rolling force, and the influence regularities of axial force of cross wedge rolling asymmetric shaft-parts is get. It will provide a theoretical basis for choosing reasonable parameters in mold design of cross wedge rolling asymmetric shaft-parts.

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