Complementary Methods for Assessment of Residual Stress Fields Induced by Rotary Swaging of Steel Bars

Charni, Dhia; Ishkina, Svetlana; Épp, Jérémy; Herrmann, Marius; Schenck, Christian; Kuhfuß, Bernd

doi:10.1007/978-3-030-75381-8_188

Cited by 2 publications

(1 citation statement)

References 12 publications

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“…In addition, it must be mentioned that the residual stress and texture formed in the RS of the bcc metal might also be influencing factors, as discussed in the research of Kocich and Charni et al [ 39 , 40 , 41 ]. The mutual effect of all these factors would change the fracture surface after swaging.…”

Section: Discussionmentioning

confidence: 99%

Effect of Rotary Swaging on Mechanical Behaviors of Axle Steel Rod

Tian,

Xu,

Zheng

et al. 2024

Materials

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The short-chain forming process using rotary swaging (RS) is an important method of achieving the manufacturing of lightweight axles. Axle steel, like 42CrMo, is widely used in many types of axles and shafts; however, there is no existing research on rotary-swaged axle steel’s mechanical properties. It makes sense to carry out a comprehensive study on the effect of RS on the mechanical behaviors of axle steel rods. In this study, a 42CrMo steel rod was processed by RS through ten passes. The tensile properties, torsion properties, compression properties, and fatigue properties were tested. There was an overall improvement in the torsional and fatigue performance after RS. Combined with a finite element analysis (FEM), the uneven distribution of the dislocations and existence of the elongation material were inferred to have caused the different modes of the mechanical behaviors. Fracture surfaces were analyzed and the results showed that the fracture pattern had changed. There existed a competitive relation between the internal fatigue cracks and external cracks, which could be attributed to uneven strain hardening. This research proved the advantages of RS in the processing of axle parts, which mainly benefitted the torsional working conditions, and provided evidence for a new processing route for lightweight axles with RS.

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Section: Discussionmentioning

confidence: 99%

Effect of Rotary Swaging on Mechanical Behaviors of Axle Steel Rod

Tian,

Xu,

Zheng

et al. 2024

Materials

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Development of residual stresses by infeed rotary swaging of steel tubes

et al. 2021

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Additionally to the achievable tight geometrical tolerances, rotary swaging can influence intrinsic material properties by work hardening and residual stresses generation. Although residual stresses should be usually avoided, they can be used on purpose to improve the performance properties of a produced part. To find prospective process settings, 2D FEM simulation of the rotary swaging process was developed and revealed the development of residual stresses distributions in E355 steel tubes in the whole longitudinal section. Besides the closing time, also geometric features of the dies were varied. It was found that the closing time affects the residual stresses significantly at the surface, but not in the depth of the part. By shortening the calibration zone, the axial tensile residual stresses near the outer surface could be lowered, while compressive residual stresses near the inner surface remained almost unaffected. By applying a higher die angle, the tensile axial residual stresses were increased while reducing the compressive axial residual stresses. Experimental investigations of residual stresses were performed by X-ray diffraction which revealed a good agreement between simulation results and physical measurements. With these findings, the rotary swaging process can be optimized for shaping residual stresses profiles to improve the performance properties of the produced parts.

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Complementary Methods for Assessment of Residual Stress Fields Induced by Rotary Swaging of Steel Bars

Cited by 2 publications

References 12 publications

Effect of Rotary Swaging on Mechanical Behaviors of Axle Steel Rod

Effect of Rotary Swaging on Mechanical Behaviors of Axle Steel Rod

Development of residual stresses by infeed rotary swaging of steel tubes

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