Numerical and experimental research on warm cross wedge rolling of hollow shafts with corrugated surface

Shi, Jiaai; Liu, Jinping; Wang, Baoyu; Shen, Jinxia

doi:10.1007/s00170-022-09379-7

Cited by 4 publications

(3 citation statements)

References 24 publications

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“…Especially for circular cross-section parts, how to use CWR method for efficient production has always been a challenge. Shi et al [15] conducted the die design for the CWR of hollow shafts with corrugated surface and demonstrated the effect of mandrel diameter on effective strain, temperature and rolling torque. Pater et al [16,17] proposed an innovative method for ball forming by cross rolling and obtained steel balls with diameter of 70 mm successfully.…”

Section: Introductionmentioning

confidence: 99%

Influence of die parameters on the deformation characteristics of cross wedge rolling steel balls: modelling, numerical simulation and experiments

Wang,

Liu

et al. 2024

Preprint

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How to choose appropriate tool parameters has always been a challenge in the cross wedge rolling (CWR) process, as different tool parameters affects the instantaneous metal deformation pattern and effective strain, thereby affecting the geometric dimensions and mechanical properties of the formed workpiece, especially for CWR steel balls with both radial and axial forming degrees of freedom. This paper proposed four novel forms of forming angle design for CWR dies and different sizes of spreading angles. The effect of different tool parameters on the deformation characteristics of CWR steel balls was analyzed using a combination of theoretical modelling and finite element (FE) simulation analysis. The analysis indicated that the axial deformation parameters increased linearly while the radial deformation parameters increasesd exponentially during the CWR process. The steel balls obtained from equal or small arc forming angles had better roundness and filling than those obtained from fixed forming angle and large arc forming angle. When the forming angle is fixed, the larger the spreading angle, the more metal volume participates in deformation per unit time, and the more severe the deformation. Finally, tool parameters with a fixed forming angle of 30° and an equal arc forming angle, as well as a spreading angle of 8°, were selected for comparative experiments on steel balls forming. The experimental results indicated that the size accuracy of steel balls obtained by equal arc forming angle was relatively high, and a larger spreading angle could improve forming efficiency significantly, which verified the reliability of FE simulation simultaneously.

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Section: Introductionmentioning

confidence: 99%

Influence of die parameters on the deformation characteristics of cross wedge rolling steel balls: modelling, numerical simulation and experiments

Wang,

Liu

et al. 2024

Preprint

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“…Moreover, the microstructure characteristics of TC4 titanium alloy hollow shafts during cross wedge rolling were revealed, and the effects of cross wedge rolling process parameters, with or without a mandrel and billet wall thickness on the phase transformation of titanium alloy, were studied. Shi et al [20] studied the CWR process of hollow shafts with corrugated surfaces. The influence of mandrel diameter on stress, effective strain, temperature distribution, rolling force and torque was analyzed by using the finite element method.…”

Section: Introductionmentioning

confidence: 99%

Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve

Sun

Yang

2023

Metals

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In this paper, an axle sleeve is formed through a combined cross wedge rolling (CWR) and hot extrusion process, and the combined forming process is simulated via finite element analysis software Deform-3D. The forming mechanism is revealed by analyzing the stress and strain distribution, the temperature variation and the metal flow law of the workpiece during CWR and hot extrusion. Combined with CWR and hot extrusion forming experiments, the feasibility of a combined rolling and extrusion process to produce an axle sleeve is verified. It has been proven that the outer steps of the axle sleeve produced through the rolling extrusion composite process are well formed, the flange extrusion cavity is full, the metal streamline is continuous, the axis of the inner hole does not easily deviate, the product quality is good and the production efficiency is high.

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“…Bulzak et al [7] compared the ball pins manufactured in hot and warm temperature. CWR products with corrugated surface were produced [8]. The composite CWR shafts made by 42CrMo and Q235 was studied in terms of deformation characteristics and effects of process parameters [9,10].…”

Section: Introductionmentioning

confidence: 99%

Investigation and prediction of central cracking in cross wedge rolling

Zhou

Sun

Wang

et al. 2022

Int J Adv Manuf Technol

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Central cracking refers to the formation of internal cavities in cross wedge rolling (CWR) products. It occurs in various materials such as aluminium/titanium alloys, steels and plasticine at room or elevated temperatures, driven by different central cracking mechanisms. However, these mechanisms are still elusive, and a unified central cracking predictive model is absent due to the complex stress states within the workpiece, including triaxial stress states, cyclic loading and severe shear effects. In this study, the underlying fracture mechanisms were revealed, and a robust unified damage model with sound physical meanings was developed using a lab-scale CWR physical model and finite element models. The physical model with the plasticine billets was built, allowing the CWR dies with different geometries rapidly 3D printed and the billets with various ductility efficiently manufactured. The central cracking transiting from brittle to ductile fracture was experimentally observed for the first time using specifically designed plasticine/flour composite samples at varying ductility. The corresponding physics-based central cracking predictive model was proposed and validated quantitatively with 60 groups of CWR tests and compared with ten existing damage models/fracture criteria. This study effectively solves the long-lasting central cracking problem in the CWR industry and enhances the scientific understanding of fracture mechanics in complex engineering applications.

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Numerical and experimental research on warm cross wedge rolling of hollow shafts with corrugated surface

Cited by 4 publications

References 24 publications

Influence of die parameters on the deformation characteristics of cross wedge rolling steel balls: modelling, numerical simulation and experiments

Influence of die parameters on the deformation characteristics of cross wedge rolling steel balls: modelling, numerical simulation and experiments

Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve

Investigation and prediction of central cracking in cross wedge rolling

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