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.

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 Forming Mechanism for Second Step on Hollow Rotor Shaft by 4-Roll Cross Wedge Rolling

2013 ◽  
Vol 288 ◽  
pp. 271-275 ◽  
Author(s):  
Yong Ming Yang ◽  
Jiu Chuan Chen ◽  
Feng Wen Cheng ◽  
Jun Zhao
Keyword(s):  
Rolling Force ◽  
Metal Flow ◽  
Energy Parameter ◽  
Second Step ◽  
Motor Shaft ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Stress Strain ◽  
Finite Element Software

It is very important for accurately grasping stress, strain, and metal flow during the hollow motor shaft rolling, and it is also foundation of forming regularity, rolling force and energy parameter. The cross wedge rolling process of hollow motor shaft was simulated through rigid-plastic finite element software deform-3D. According to the simulation results, the distribution of internal stress, strain field inside the second step of the motor shaft had been obtained, revealed the metal flow ruler for the second step during forming process and it could effected on the metal flow ruler for the first step.

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.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

scholarly journals Numerical and Experimental Study on the Thermodynamic Coupling of Ti-6Al-4V Blade Preforms by Cross Wedge Rolling

Metals ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 1054 ◽  
Author(s):  
Hongchao Ji ◽  
Jianwei Dong ◽  
Long Xin ◽  
Xiaomin Huang ◽  
Jinping Liu
Keyword(s):  
Titanium Alloy ◽  
Metal Flow ◽  
High Strength ◽  
High Heat ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Finite Element Software ◽  
Distribution Laws ◽  
Aero Engines ◽  
Thermodynamic Coupling

Titanium alloy possesses high strength, good corrosion resistance, and high heat resistance; thus, it is widely used in the aerospace and other fields. Blades of titanium alloy are important components of aero-engines and are essential to the engines operation. In this work, a Ti-6Al-4V blade was formed by cross wedge rolling (CWR) to realize the near net-shape of an aero-engine blade. First, thermal simulation experiments of Ti-6Al-4V were carried out to obtain the thermal deformation constitutive equation of the alloy. The finite element software Deform-3D was then used to simulate the thermodynamic coupling of the forming process, and the metal flow, temperature, and stress–strain distribution laws during the forming process were analyzed. Finally, experimental verification of the Ti-6Al-4V blade was carried out by using an H500 CWR mill. The results revealed the feasibility of applying CWR to preform Ti-6Al-4V blades.

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.

Law of Metal Flow of Thin-Walled Conical Part With Variable Section During Spinning

2020 ◽  
Author(s):  
Shu Xuedao ◽  
Xia Yingxiang ◽  
Zhu Ying ◽  
Li Zixuan ◽  
Ye Bohai
Keyword(s):  
Metal Flow ◽  
Conical Part ◽  
Forming Process ◽  
Finite Element Software ◽  
Axial Tensile ◽  
Variable Section ◽  
Spinning Process ◽  
Thin Walled ◽  
Forming Defects

Abstract During the spinning process of the variable-section thin-walled conical parts, the metal flow law is relatively complicated and the flange is prone to be unstable, which resulting in wrinkling and other defects. In this paper, the variable-section conical part of superalloy GH1140 is taken as the research object. The spinning forming process is numerically simulated by using Simufact Finite Element software and the metal flow in each stage of the forming process is analyzed. The flow velocity shows an annular distribution as a whole. The metal near the center of the circle flows more slowly, and the metal far from the circular flange flows more quickly. In the direction of thickness, the velocity of metal flow decreases gradually. Under the feeding action of the roller, the metal in front of the roller is subjected to axial tensile stress, tangential and radial compressive stress, resulting in a strain state of one-way tension and two-way compression. The metal moves along the negative direction of the rotary wheel feed, resulting in the increase of the sheet wall thickness. The correctness of the model in this paper is further verified by spinning experiments. The research results provide a theoretical basis for analyzing the mechanism of forming defects and improving the quality of spinning forming of conical thin-walled parts with variable sections.

Stress-Strain Analysis of the Sun Shaft in Cross-Wedge-Rolling

2014 ◽  
Vol 941-944 ◽  
pp. 1757-1760
Author(s):  
Peng Biao Han ◽  
Xiao Xi He ◽  
Hua Jun Yan ◽  
Jun Li ◽  
Zhao Zhang ◽  
...  
Keyword(s):  
Rule Of Law ◽  
Basic Characteristic ◽  
Metal Flow ◽  
Strain Analysis ◽  
Basic Rule ◽  
The Sun ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Stress Strain

Analysis of the basic characteristic of cross wedge rolling forming process and the stress -strain research at various stages are summed up in order to obtain the basic rule of law and the metal flow regular during forming.

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.

Numerical Simulation of the Effect of Feedstock Shape on Continuous Extrusion Process

2012 ◽  
Vol 472-475 ◽  
pp. 2004-2008 ◽  
Author(s):  
Li Chen ◽  
Bao Yun Song ◽  
Xin Bing Yun
Keyword(s):  
Metal Flow ◽  
Flow Characteristics ◽  
Extrusion Process ◽  
Forming Process ◽  
Section Shape ◽  
Wheel Torque ◽  
Metal Deformation ◽  
Continuous Extrusion ◽  
Extrusion Forming ◽  
3D Software

Since the appearance of the continuous extrusion process, the section shape of the feedstock is round. The shape of the feedstock directly affects metal deformation and metal flow characteristics during the continuous extrusion process. Based on finite element method (FEM), using the Deform-3D software, this paper simulates continuous extrusion forming process for copper bus bar, and analyzes the effect of different feedstock shape on metal flowing temperature, velocity, rotating torque. The results show that: the size of the rectangular feedstock must be within a reasonable range, otherwise the continuous extrusion process can not be established; the rectangular feedstock is benefit to the flow uniformity comparing with the round feedstock; the temperature of the billet and tooling with rectangular feedstock is lower than that with round feedstock, as the feedstock width increases, the temperature decreases and the area of high temperature becomes smaller; the change of the feedstock shape and size has no effect on the extrusion wheel torque value.

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