Study on the deformation mechanism for forming shafts without concavity during the near-net forming cross wedge rolling process

Zeng, Jian Min; Xu, Chunguo; Ren, Weiwei; Li, Pan

doi:10.1007/s00170-016-9742-6

Cited by 11 publications

(3 citation statements)

References 6 publications

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“…The rolling process of multi-step shafts always starts from a certain plane in the middle to both ends for metal shaping and the influence of plastic metal on the concave size of the rolling end will decrease with the increasing of the distance from the shaft end [ 19 , 20 ]. Consequently, in order to reduce the quantity of calculation and enhance calculation efficiency, when using DEFORM-3D software for finite element simulation, a three-diameter shaft was selected as the research object, and contact surface constraint was applied to the middle of a certain plane, as shown in Figure 4 .…”

Section: Methodsmentioning

confidence: 99%

Study on Near-Net Forming Technology for Stepped Shaft by Cross-Wedge Rolling Based on Variable Cone Angle Billets

Han

Shu

2018

Materials

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Considering problems about concaves at the stepped shaft ends, this paper established the plastic flow kinetic theories about metal deforming during the cross-wedge rolling (CWR) process. By means of the DEFORM-3D finite element software and the point tracing method, the forming process of stepped shafts and the forming mechanism of concaves at shaft ends were studied. Based on the forming features of stepped shafts, rolling pieces were designed using variable cone angle billets. Single-factor tests were conducted to analyze the influence law of the shape parameters of billet with variable cone angle on end concaves, and rolling experiments were performed for verification. According to the results, during the rolling process of stepped shafts, concaves will come into being in stages, and the increasing tendency of its depth is due to the wave mode, the parameters of cone angle α, the first cone section length n. Furthermore, the total cone section length m has an increasingly weaker influence on the end concaves. Specifically, cone angle α has the most significant influence on the quality of shaft ends, which is about twice the influence of the total cone section length m. The concave depth will decrease at the beginning, and then increase with the increasing of the cone angle α and the first cone section length n, and it will decrease with the increasing of the total cone section length m. Finite element numerical analysis results are perfectly consistent with experimental results, with the error ratio being lower than 5%. The results provide a reliable theoretical basis for effectively disposing of end concave problems during CWR, rationally confirming the shape parameters of billets with a variable cone angle, improving the quality of stepped shaft ends, and realizing the near-net forming process of cross-wedge rolling without a stub bar.

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Section: Methodsmentioning

confidence: 99%

Study on Near-Net Forming Technology for Stepped Shaft by Cross-Wedge Rolling Based on Variable Cone Angle Billets

Han

Shu

2018

Materials

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“…Numerous studies have been conducted to reduce material losses in CWR. Zeng et al [ 59 ] used Deform 3D to that end, finding that this defect could be controlled by using profiled billets (with tapered or circular-arc ends). Guo and Lu [ 60 ] determined the effect of angles α and β and area reduction Δ A on the volume of defective ends.…”

Section: Formation Of Concavities On the Workpiece Endsmentioning

confidence: 99%

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Pater

2023

Materials

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The aim of this article is to review the application of the finite element method (FEM) to cross-wedge rolling (CWR) modeling. CWR is a manufacturing process which is used to produce stepped axles and shafts as well as forged parts for further processing on forging presses. Although the concept of CWR was developed 140 years ago, it was not used in industry until after World War 2. This was due to the limitations connected with wedge tool design and the high costs of their construction. As a result, until the end of the twentieth century, CWR tools were constructed by rolling mill manufacturers as they employed engineers with the most considerable experience in CWR process design. The situation has only changed recently when FEM became widely used in CWR analysis. A vast number of theoretical studies have been carried out in recent years, and their findings are described in this overview article. This paper describes nine research areas in which FEM is effectively applied, namely: the states of stress and strain; force parameters; failure modes in CWR; material fracture; microstructure modeling; the formation of concavities on the workpiece ends; CWR formation of hollow parts; CWR formation of parts made of non-ferrous materials; and new CWR methods. Finally, to show the potential of FEM on CWR modeling, a CWR process for manufacturing a stepped shaft used in car gearboxes is simulated numerically. This numerical simulation example shows that FEM can be used to model very complex cases of CWR, which should lead to a growing interest in this advanced manufacturing technique in the future.

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“…Shortcomings of this solution include a relatively high length of the wedge block as well as the possibility of overlap formation. The third method of end waste elimination was to use profiled billets with tapered and circular-arc ends [14,15], as well as variable cone angle ends [16]. The profiled ends would be shaped in a separate operation which, in some cases (tapered ends), could be combined with roll cutting a bar into a conical end blank.…”

Section: Introductionmentioning

confidence: 99%

Multi-Variant Analysis of the Cross Wedge Rolling Process for Producing Railcar Axles

Pater,

Tomczak,

Bulzak

2023

Adv. Sci. Technol. Res. J.

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This study investigates the cross wedge rolling (CWR) process for manufacturing a rail axle in a scale of 1:6. Three cases of the rolling process are modelled numerically: standard rolling, wasteless rolling and rolling from a preform. The rolling cases under analysis are compared in terms of material and energy consumption, forming loads as well as propensity to internal and external defect formation. Using the Cockcroft-Latham criterion and the limits of this criterion determined by the rotary compression test, an assessment was made of the propensity of the material to fracture during the rolling processes analysed. Based on numerical results, standard CWR is selected for experimental verification. Obtained experimental results confirm that CWR is an effective method for producing railcar axles that are free from both internal and external defects. The experimental and numerical results obtained confirm that cross wedge rolling technology can be successfully used under industrial conditions for the production of long axles or shafts.

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Study on the deformation mechanism for forming shafts without concavity during the near-net forming cross wedge rolling process

Cited by 11 publications

References 6 publications

Study on Near-Net Forming Technology for Stepped Shaft by Cross-Wedge Rolling Based on Variable Cone Angle Billets

Study on Near-Net Forming Technology for Stepped Shaft by Cross-Wedge Rolling Based on Variable Cone Angle Billets

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Multi-Variant Analysis of the Cross Wedge Rolling Process for Producing Railcar Axles

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