Research and prospect of flexible forming theory and technology of hollow shaft by three-roll skew rolling

Shu, Xuedao; Zhang, Song; Chen, Shu; Wang, Jitai; Ye, Caoqi; Xia, Yingxiang; Essa, Khamis; Pater, Z.

doi:10.1007/s00170-022-10242-y

Cited by 15 publications

(5 citation statements)

References 15 publications

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“…Gear shafts are stepped shafts with gears, and are key components of the transmission system in mechanical equipment. The deformation in the manufacturing of gear shafts is larger and more complex than those in ordinary stepped shafts and hollow shafts with the conventional manufacturing techniques [4] [5].How to realize high-performance manufacturing of gear shafts is a cutting-edge topic. Scholars from different countries have carried out researches from various perspectives.…”

Section: Introductionmentioning

confidence: 99%

Study on the regulation of deformation uniformity and microstructure law in the forming of gear shafts by cross wedge rolling

Lulu,

Xuedao,

Xiaogu

et al. 2024

Int J Adv Manuf Technol

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Gear shafts are commonly manufactured by machining of gear teeth and shaft separately. This kind of approach entails quite some problems, such as long processing time, large die and low production efficiency. To tackle these problems, this paper innovatively proposes a new process of cross wedge rolling (CWR) that is specifically tailored to the manufacturing of gear shafts, with which the shaft and teeth are formed at one go. The finite element model of CWR forming of gear shaft is established to simulate and analyze the CWR forming process. A three-factor and three-level response surface test is designed to optimize the processing parameters, where the friction coefficient, rolling temperature and die movement speed are chosen as three factors, and inhomogeneous deformation is set as the response. The optimal parameters are obtained as follows: the rolling temperature is 1240 ℃, the speed of the die movement is 336 mm/s, and the friction coefficient is 0.8. This result is subsequently verified by experiments. Further on, the microstructure evolution of the characteristic points of the CWR forming process of gear shaft are analyzed. It is found that the grains at the gear teeth section are continuously refined and grown from the boundary at the early section of deformation, and the final grains grown are much smaller than the original ones. In addition, the grains appear to grow in a short range of time in the process of deformation, but the overall trend is towards refinement. In the shaft section, the evolutions of the grains in the two stepped shaft segments are almost the same; the grain deformation shows cyclic changes; the degree of grain refinement in the shaft is higher than that in the teeth; and the degree of grain refinement in the shaft center is higher than that in the shaft edge. The results of the study provide a theoretical basis for short-process forming of high-performance gear shafts by cross wedge rolling.

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Section: Introductionmentioning

confidence: 99%

Study on the regulation of deformation uniformity and microstructure law in the forming of gear shafts by cross wedge rolling

Lulu,

Xuedao,

Xiaogu

et al. 2024

Int J Adv Manuf Technol

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“…Based on the analysis results, a three-roll skew rolling mill was designed and manufactured. Zhang [15,16] studied the wall thickness uniformity of three-roll skew rolled hollow shafts with constant hole diameters. The influence of different process parameters on wall thickness uniformity is explained.…”

Section: Introductionmentioning

confidence: 99%

The Mechanism of Forming Hollow Shafts with Constant Wall Thickness by Three-Roll Skew Rolling

Zhang,

Shu,

Wang

et al. 2024

Metals

Self Cite

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To solve the problem of the long forming process for hollow shafts with constant wall thickness (HSCWT), a new process for forming HSCWT, namely three-roll skew rolling, has been proposed. First, the working principle of the three-roll skew rolling process is presented. Then, the finite element model (FEM) of the three-roll skew rolling HSCWT is established. The strain-stress field and temperature field distribution rules of the three-roll skew rolling HSCWT are analyzed with FEM. The stress-strain field of the rolled piece is distributed uniformly along the axial direction but not uniformly along the radial direction. The variation of the temperature field is related to the axial traction velocity. The greater the axial traction velocity, the smaller the variation of the temperature field. The temperature of rolled pieces varies within 100 °C during rolling. Finally, the three-roll skew rolling experiment of the HSCWT is carried out. The results show that the three-roll skew rolling process can form HSCWT. The temperature field of the three-roll skew rolling HSCWT is evenly distributed. The selection of larger axial traction velocity is conducive to the forming of rolled pieces. The three-roll skew rolling technology has achieved near constant temperature forming of HSCWT.

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“…This, however, is not a serious defect, as the grooves can be removed by machining. Experiments have also been conducted on rolling hollow steel parts with variable cross section [8][9][10]. The use of hollow tubes made it possible to avoid additional processing operations such as drilling, as well as to prevent unnecessary material loss which occurs when hollow parts are formed from solid billets.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Waviness Values in Skew Rolling Using Machine Learning Methods

Lis,

Pater,

Tomczak

et al. 2023

Adv. Sci. Technol. Res. J.

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This paper relates to the selection of a machine learning model for predicting the surface waviness of rolled products. An experimental study was carried out using the skew rolling method with three tapered rolls. The products were shaped with variable process parameters. The obtained results were used as a training data set for selected regression models. The random forest model was determined to be the most effective due to the highest value of the coefficient of determination R 2 . The influence of individual process parameters on the waviness value was calculated using the SHAP library.

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Research and prospect of flexible forming theory and technology of hollow shaft by three-roll skew rolling

Cited by 15 publications

References 15 publications

Study on the regulation of deformation uniformity and microstructure law in the forming of gear shafts by cross wedge rolling

Study on the regulation of deformation uniformity and microstructure law in the forming of gear shafts by cross wedge rolling

The Mechanism of Forming Hollow Shafts with Constant Wall Thickness by Three-Roll Skew Rolling

Prediction of Waviness Values in Skew Rolling Using Machine Learning Methods

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