The Development of the Method for the Calculation of the Shaping Force in the Production of Vehicle Wheel Rims

Abstract

The objective of the paper is the development of the method for the calculation of the required force of shaping of a horizontal shape-forming machine used in the preproduction workflow. The design of a machine for horizontal shape-forming of wheel steel rims enables quick readjusting and transfer to another rim shape, which is significant under the conditions of frequent alteration of the product nomenclature. We developed the calculation method based on the assumptions of the deformations continuity, the constancy of the volume at plastic deformation and axisymmetric stressed state as well as the local application of the load. The research resulted in obtaining the analytical dependences for the calculation of the force of shaping of a wheel rim, taking into account the degree of deformation, the mechanical characteristics of the metal, hardening as well as the design and technological factors of the process. The topicality of the development consists in the necessity for the high-quality and the least expensive choice of the equipment of the required rated power when designing a new workflow. The experimental data, carried out both under the production and laboratory conditions, confirmed the adequacy of the theoretical formulas. It is determined by the assumptions and solutions obtained based on the mathematical apparatus of the technical theory of the shells of revolution. The clearness of the method will make it possible to algorithmize the calculation process quite easily and to use it as a subprogram in an applied complex of technical preproduction. It will also allow determining the shaping process most significant factors influencing the value of the force without the direct use of the calculation. We recommend to use it at enterprises producing vehicle steel wheels by the method of radial-rotation shaping.

The research thermoplastic deformation modes of dual-phase special alloys for obtaining rational intermetallic structure

“…On the basis of the results of the above papers [5][6][7][8][9][10][11][12][13][14][15] and the earlier self-study results of the thermochemical pressing process [5,6,14], an attempt was made to determine the basic patterns of deformation and structure formation, to determine the ways and methods of controlling the processes of forming the structure and properties of compressed articles under conditions SHS In order to solve the problem, the method of mathematical modeling is used, in the implementation of which can be conditionally distinguished the following main stages: the idealization of internal properties of the given process (object) and external influences (construction of the physical model); mathematical formulation of the behavior of a physical model (construction of a mathematical model); choice of method for studying a mathematical model and conducting this research; analysis of the obtained mathematical result.…”

Development of rational chemical composition of special steel with increased mechanical and performance characteristics

“…According to the operating conditions, the wheel must meet a number of requirements that ensure traffic safety and the economic performance of the vehicle. First of all, this is the strength of all its parts, the rigidity and quality of wheel rims, fasteners, minimal runout and imbalance of wheels [2]. In the automotive industry, steels are widely used, which have high ductility and strength, which are easily deformed in industrial conditions.…”

FEM simulation of bending and torsion tests of similar size RHS but of the different production options

“…For the manufacture of structural sections with required service properties different fabrication methods are used [1,[6][7][8][9][10][11][12]: skew roll piercing process, pilger process, Fretz-Moon pipe process, induction welding process, spirally bent strip welding. Hot-finished process (HFP) [13][14][15][16] and cold-formed process (CFP) [7,[10][11][12] is the most common manufacturing for RHS. These consist in the roll-forming of circular tube from a strip, welding of edges and re-forming into rectangular tube section (round to square or rectangular section forming) with heating (HFP) or without heating (CFP), respectively.…”

“…The improvement of designs, process of production and quality control of these products is constantly given considerable attention due to their high importance and adaptation to different ranges of use. Therefore, the development of methods of modeling of the section behavior of various (including improved) structures remains extremely relevant [4][5][6][7][18][19][20], because allows to identify the advantages and disadvantages of new solutions and develop recommendations for improving the processes of manufacturing structural sections. Research on stiffness of structural sections is conducted by bending and torsion tests.…”