The aspects of stability in cross-wedge rolling processes of hollowed shafts

Bartnicki, J.; Pater, Z.

doi:10.1016/j.jmatprotec.2004.04.278

Cited by 59 publications

(27 citation statements)

References 2 publications

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“…Cross wedge rolling is also widely used for forming billets for the die forging of elongated parts. In addition, the CWR technique can be employed to produce such parts as toothed shafts, screw spikes and balls [3][4][5][6]. In the past, some research was undertaken to investigate the application of CWR for producing twist drills [7].…”

Section: Introductionmentioning

confidence: 99%

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Tofil¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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The paper presents a selection of numerical and theoretical results of the cross wedge rolling process for producing stepped shafts made of aluminum alloy 6061. The numerical modeling was performed using the FEM-based Simufact Forming simulation software. In the simulations, we examined the kinematics of metal flow and determined the distribution patterns of effective strains, temperatures, axial stresses and the Cockroft-Latham damage criterion. Variations in the rolling forces were determined, too. The numerical results were verified experimentally using a universal rolling mill designed and constructed by the present authors. This machine can be used to perform such processes as cross wedge rolling, longitudinal rolling and round bar cropping. During the experiments, we examined process stability and finished product geometry and recorded the torques. The experimental results confirm that axisymmetric aluminum alloy shafts can be produced by cross wedge rolling with two rolls. Last but not least, the experiments served to evaluate the technological potential of the rolling mill used.Keywords: cross wedge rolling, aluminum alloys, FEM, experiment W pracy przedstawiono wybrane wyniki badań teoretyczno -doświadczalnych procesu walcowania poprzeczno -klinowego odkuwki wałka stopniowanego ze stopu aluminium w gatunku 6061. Analizę teoretyczną przeprowadzono w programie Simufact Forming, bazującym na metodzie elementów skończonych. W trakcie symulacji analizowano kinematykę płynięcia materiału, wyznaczono rozkłady intensywności odkształcenia, temperatury, naprężeń w kierunku osiowym oraz kryterium zniszczenia wg Cockrofta Lathama. Ponadto określono parametry siłowe podczas walcowania. Weryfikacji doświadczalnej wyników modelowania numerycznego procesu walcowania dokonano w uniwersalnej walcarce kuźniczej, która stanowi własna konstrukcję. Zastosowana walcarka umożliwia realizacje takich procesów jak: walcowanie poprzeczno-klinowe, walcowanie kuźnicze wzdłużne oraz dzielenie bezodpadowe. Podczas eksperymentu analizowano stabilność procesu, geometrie ukształ-towanych odkuwek oraz rejestrowano wartość momentów obrotowych. Uzyskane wyniki prowadzonych badań potwierdziły możliwość kształtowania osiowosymetrycznych odkuwek ze stopów aluminium metodą WPK dwoma walcami. W trakcie eksperymentu określono również możliwości technologiczne walcarki.

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Section: Introductionmentioning

confidence: 99%

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Tofil¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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show abstract

“…The results reported by Bartnicki in [12] demonstrate that the smaller the wall thickness of the hollow billet used in CWR, the more likely the risk of uncontrolled slipping and product crushing is. The production of hollow parts by CWR with flat wedges is considerably limited by the potential occurrence of uncontrolled slipping that can cause crushing of the shaft step being formed [13,14].…”

Section: Introductionmentioning

confidence: 94%

The influence of hollow billet thickness in rotary compression

Tomczak

Pater

Bulzak

2015

Int J Adv Manuf Technol

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The study presents a selection of numerical and experimental results of producing hollow stepped shafts. The first part of this study describes the advantages of using hollow parts in machine design and discusses the main fields of their applications. Next, an innovative rotary compression method for producing stepped axes and shafts is proposed. In order to estimate the technological potential of rotary compression, we performed comprehensive numerical and experimental analyses of producing hollow stepped shafts by this new technique. First, the rotary compression process for hollow parts was modeled numerically by the finite element method. The 3D modeling was made using the Simufact Forming software. The numerical results were then verified by experimental tests conducted under laboratory conditions. The experiments were performed using a machine designed by the authors of the present study. The following variables were investigated in the experiments: the effect of billet wall thickness on the process, the quality and geometry of products, and variations in loads and torques. The experimental results confirm that rotary compression can be used to produce hollow stepped shafts with a wide range of thicknesses.

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“…The wider applications are connected with two rolls and two flat tools solutions. Because of simplicity of tooling processes, the latest method is the cheapest in applications, but in the case of hollow part forming the most interesting is solution with three rotating tools -wedges [1][2][3][4]. Fig.…”

Section: Cross Wedge Rolling (Cwr)mentioning

confidence: 99%

“…In order to meet these requirements, it is necessary to look for new solutions, both at the designing stage and during manufacturing. Efficiency is very often the most important economical criterion, which, by no means, highlights the advantages of metal forming in comparison with machining process [1][2][3][4]. This paper presents the numerical analysis results of the stepped, hollow shaft manufacturing by means of cross wedge rolling technology.…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the Cross-Wedge Rolling Process by Means of Three Tools of Stepped Shafts From Aluminum Alloy 7075

Bartnicki

Tomczak

Pater

2015

Archives of Metallurgy and Materials

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This paper presents results of numerical calculations for the rolling process by means of three tools of stepped shafts from aluminum alloy 7075. Forming with the usage of tools with three different wedge spreading angles underwent analysis. In the paper, the obtained distributions of stresses, strains and Cockcroft-Latham damage criterion were given. Moreover, the influence of the wedge spreading angle on shape faults presence in the obtained product was determined. At the same time, the force parameters, which play a crucial role in the designed experiment, were analyzed.Keywords: Cross -wedge rolling, FEM, stepped shafts W artykule przedstawiono wyniki obliczeń numerycznych dla procesu walcowania trzema narzędziami wałków stopniowanych ze stopu aluminium 7075. Analizą objęto kształtowanie za pomocą narzędzi o trzech różnych kątach rozwarcia klina. W pracy podano uzyskane rozkłady naprężeń, odkształceń oraz kryterium pękania wg całki Cockrofta -Lathama. Ponadto, określono wpływ kąta rozwarcia klina na powstawanie błędów kształtu w uzyskiwanym wyrobie. Równolegle przeanalizowano parametry siłowe, których wyznaczenie ma kluczową rolę w projektowanym eksperymencie.

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The aspects of stability in cross-wedge rolling processes of hollowed shafts

Cited by 59 publications

References 2 publications

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

The influence of hollow billet thickness in rotary compression

Numerical Analysis of the Cross-Wedge Rolling Process by Means of Three Tools of Stepped Shafts From Aluminum Alloy 7075

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