Analysis of a cross wedge rolling process for producing drive shafts

Abstract

The paper discusses the problems of forming parts such as stepped shafts by cross wedge rolling (CWR). In industrial practice, this rolling process is performed at stages, i.e., in several passes, when large cross-sectional reductions are involved. The same can also be done using a different design of this forming process, namely, multi-wedge cross rolling (MWCR), in which the workpiece is simultaneously formed by several pairs of tools (wedges). This paper compares the above two methods with respect to forming a drive shaft. Wedge tools used in both forming processes are described, and the numerical results of the simulations performed to verify the adopted solutions are reported. The results demonstrate that the MWCR method offers more advantages than the classical CWR technique. Consequently, MWCR is then verified in experimental tests. The experimental results confirm that parts such as stepped shafts can be formed by the MWCR method.

Effect of Tool Kinematics on Tube Flanging by Extrusion with a Moving Sleeve

“…The coefficient of heat transfer between the workpiece and the tools was set equal to 10 kW/m 2 K. The upper and lower punch velocities were set equal to 10mm/s, while the velocity of the moving sleeve was calculated based on Eqs. (1) and (2) for Case 1 and Case 2, respectively. The initial temperature of both the tools and the billet was set equal to 20˚C.…”

“…Cross wedge rolling (CWR) can be used to produce stepped shafts, both hollow [1] and solid [2,3]. In this process the workpiece is deformed by tools in the form of plates or rolls with shaping wedges on their surface.…”

Research and industrialization of near-net rolling technology used in shaft parts

“…CWR is usually applied in the metal forming industry for the manufacture of elongated products, such as stepped shafts [6][7][8][9], balls [10], and preforms of forging [11][12][13][14][15][16][17].…”

FEM Analysis of Loads and Torque in a Skew Rolling Process for Producing Axisymmetric Parts

“…Instead, the workpiece is fastened in fixed plane, while the axial motion of the chuck is replaced with axial feed of the rolls, which does not affect the kinematics of this process and facilitates the numerical simulation (axial load on the chuck is defined by a sum of axial loads acting on the rolls). This model of skew rolling was previously used by the author to investigate the skew rolling process for a axle [6] and a stepped shaft used in light trucks [8]. The skew rolling process is defined by the following variables ( Fig.…”

“…If the motion of the rolls and chuck is set accurately, it is possible to manufacture products of various shapes using the same set of tools. It should be emphasized that the skew rolling process is performed at relatively low loads and torques, which means reduced energy consumption of this manufacturing process [5][6][7].…”