A sheet blank rotary forging process for disk-like parts with thickened rims

Abstract

Disk-like parts with both thin web plates and thick rims are widely applied in automotive and aviation industries. These parts are usually made via welding and machining, which often lead to low material utilization, high energy consumption and low product performance. Therefore, a new sheet blank rotary forging process for thickening the rims of disc-like sheet blanks with uniform thicknesses was proposed in this paper. Based on FEA and experiments, both the effects of main defects and process parameters on forming were investigated. Besides, by considering the flow line distribution in formed parts, the material deformation feature in the forming process was analyzed. The results showed that the deformation process can be divided into four stages, and there are mainly four kinds of defects occurring during forming. Materials in the outer side of rim flows not only in the radial direction but also in the tangential direction.

Determining experimentally the stress-strained state in the radial rotary method of obtaining wheels rims

“…The obtained data confirm similar studies on the measurement of deformations, which were cited above [1][2][3][4][5], but they were carried out under manufacturing conditions on the full-scale models of the rims. The places of radius transitions undergo the effect of the largest stretching deformations, where their localization takes place, which leads to local thinning of metal in these zones.…”

“…However, this method is connected with a large quantity of measurements and requires precise calibration of tensoresistors and skilled researchers. The interpretation of the results by some authors [1,2] may differ radically from that of others [3]. At the same time, practical results of these articles are of particular nature, they can be used for specified wheels and, therefore, the authors themselves expressed a wish about necessity of conducting studies for other standard sizes.…”

“…The complexity of experimental and theoretical analysis of the radial rotary profiling of the rims of wheels is noted by many authors of the studies on the discussed topic [1][2][3][4], and for now there are no clear recommendations on determining the main indicators of the stress-strained state with regard to locality of the load application. Thus, the article [5] provides qualitative characteristics in connection to the distribution of deformations and stresses in the different sections of the wheel's profile but the information about the method of their determining and the data on their quantitative assessment are absent.…”

“…Thus, the article [5] provides qualitative characteristics in connection to the distribution of deformations and stresses in the different sections of the wheel's profile but the information about the method of their determining and the data on their quantitative assessment are absent. In the papers [1][2][3], the stress-strained state was determined by the method of tensometry, by gluing the sensors on a workpiece in the tested zone. For registering indications of tensoresistors, they used expensive high-precision equipment of the analog-to-digital type of converters and operational amplifiers.…”

“…And while the technology of manufacturing the wheels disks by the methods of sheet stamping is explored quite well, the questions concerning the radial rotary profiling as one of the progressive methods of manufacturing the rims, remain insufficiently examined and open [1,2].…”