A Rotary Compression Process for Producing Hollow Gear Shafts

Tofil, Arkadiusz; Tomczak, J.; Bulzak, Tomasz; Pater, Z.; Buczaj, M.; Sumorek, A.

doi:10.3390/ma13245718

Cited by 3 publications

(5 citation statements)

References 20 publications

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“…With lower feed rates, the wall thickness increases, and vice versa, until the product stability is lost. This phenomenon has already been analyzed in previous studies on rotary compression and rolling extrusion processes [2,5,16], where the changing proportions of the axial and radial flow of material in these processes were analyzed. In the process of skew rolling of hollow products, this phenomenon is analogous, but the wall thinning does not occur in any of the examined cases.…”

Section: Discussionmentioning

confidence: 93%

“…The presented works in the field of forming hollow products with the direct possibility of implementation into small-lot production concern, among others, rotary compression technology [ 16 ], where the obtained filled or hollow product is rolled by approaching rotating roller tools. This method, apart from offering significant advantages, has a limitation related to the modeling of the wall thickness of the resulting hollow product.…”

Section: Introductionmentioning

confidence: 99%

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The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

2021

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The paper presents chosen aspects of the skew rolling process of hollow stepped products with the use of a skew rolling mill designed and manufactured at the Lublin University of Technology. This machine is characterized by the numerical control of spacing between the working rolls and the sequence of the gripper axial movement, which allows for the individual programming of the obtained shapes of parts such as stepped axles and shafts. The length of these zones and the values of possibly realizable cross-section reduction and obtained outlines are the subject of this research paper. The chosen results regarding the influence of the technological parameters used on the course of the process are shown in the present study. Numerical modelling using the finite element method in Simufact Forming, as well as the results of experimental tests performed in a skew rolling mill, were applied in the conducted research. The work takes into account the influence of cross-section reduction of the hollow parts and the feed rate per rotation on the metal flow mechanisms in the skew rolling process. The presented results concern the obtained dimensional deviations and changes in the wall thickness determining the proper choice of technological parameters for hollow parts formed by the skew rolling method. Knowledge about the cause of the occurrence of these limitations is very important for the development of this technology and the choice of the process parameters.

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Section: Discussionmentioning

confidence: 93%

Section: Introductionmentioning

confidence: 99%

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

2021

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“…Obtained results of the σ x /σ F ratio are shown in Figs. 18 and 19 for two-and three-roll CWR, respectively.…”

Section: Core Necking (Rupture)mentioning

confidence: 99%

“…In this process the workpiece was deformed into the desired shape during two revolutions of three coupled rolls. Three-roll CWR also became a basis for developing new methods for manufacturing hollow parts, including cross wedge rolling by means of one flat wedge and two shaped rolls [17], rotary compression with the use of rolls [18,19], and three-roll rolling with eccentrically mounted tool segments [20].…”

Section: Introductionmentioning

confidence: 99%

A Comparison of Two-Roll and Three-Roll Cross Wedge Rolling Processes

Pater¹

2023

Adv. Sci. Technol. Res. J.

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Cross wedge rolling (CWR) is used for producing stepped axles and shafts as well as die forging preforms. In current industrial practice, CWR conducted with two tools is predominantly used, with the wedges mounted on rolls or flat tool plates. However, CWR can also be performed with the use of three wedge rolls. This paper begins with a review of previous studies on CWR conducted with the use of three rolls. After that, numerical simulations of two-and three-roll CWR processes for the same shaft are described. Obtained numerical results are then used to compare the two processes in terms of material flow kinematics, material temperature, stresses and strains, failure modes, as well as load and energy parameters. Finally, the Conclusions section presents the advantages of threeroll cross wedge rolling, providing a good starting point for further research on this promising forming method.

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“…Rotary compression allows one to form hollow elements freely or use a calibrating mandrel to create the inner hole [7]. Rotary compression allows one to manufacture the following hollow elements: rails, axles, stepped shafts and worm gear shafts [8]. The characteristics of this technology are high quality and low cost of the tools.…”

Section: Introductionmentioning

confidence: 99%

FEM analysis of the manufacturing of hollow forgings from a tube billet

Bulzak

Winiarski

Wójcik

et al. 2021

J. Phys.: Conf. Ser.

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The study presents an analysis of the manufacturing process of a hollow forging. The process was proposed to consist of three stages. In the first stage (extrusion) wall thickness was reduced and the flange was formed. In the two subsequent stages the flange was formed. The material flow was examined using FEM. The issue of defect occurrence in the area of a hole caused by the material moving away from the mandrel was especially researched. Moreover, the strain state was analysed in the following forging operations. The distribution of the fracture criterion was presented. Moreover, a prediction of the forces necessary for the process to be performed in real conditions was carried out. The conclusion is that the proposed scheme of forming hollow forgings may be implemented in industrial conditions.

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A Rotary Compression Process for Producing Hollow Gear Shafts

Cited by 3 publications

References 20 publications

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

A Comparison of Two-Roll and Three-Roll Cross Wedge Rolling Processes

FEM analysis of the manufacturing of hollow forgings from a tube billet

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