Effect of Blank Shape and Size on the Forming Quality of Thread Shaft Rolling in Cross Wedge Rolling

Yan, Hua Jun; Mao, Hao En; Li, Guo Chang; He, Xiao Jun; Liu, Jin Ping; Zheng, Huayan

doi:10.4028/www.scientific.net/amr.853.605

Cited by 4 publications

(5 citation statements)

References 2 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…square, oval, hexagonal), formed by tools with specially profiled forming surfaces [7][8][9]. The rolling of such parts is characterized by oscillatory variations in the forces resulting from cyclic changes in reduction ratio;  CWR for toothed or worm shafts using tailor-made inserts fixed behind the sizing zone of the tools [10][11][12][13][14];  CWR for hollow parts performed with an elongated sizing zone of the tools [3,[15][16][17][18][19][20][21];  CWR for products made of non-ferrous materials such as titanium alloys [22][23][24], aluminum alloys [12], magnesium alloys [25], superalloys based on nickel [26] and copper [27];  multi-wedge rolling in which the workpiece is formed simultaneously by more than one pair of tools. This rolling technique is used in the production of very long axles and shafts (e.g.…”

Section: New Trends In the Cwr Techniquementioning

confidence: 99%

A New Cross Wedge Rolling Process for Producing Rail Axles

Pater

Tomczak

2018

MATEC Web Conf.

View full text Add to dashboard Cite

Rail axles are large-size parts produced in large batches. Currently, these parts are produced by metal forming techniques such as rotary forging, open die forging with hydraulic presses and open die hammer forging (minimum ram weight: 3 Mg). Nevertheless, not only are the above methods far from being efficient, they also lack accuracy (open die forging). As a result, new techniques for producing rail axles are constantly developed. One of such alternative techniques is based on the use of cross wedge rolling (CWR), which is the subject of the present study. An innovative roll design for producing rail axles by CWR is proposed. The rolls are provided with three pairs of wedge tools that act simultaneously on the workpiece and form the part in one revolution of the rolls, i.e., during 20 s. The numerical modelling of a CWR process with the proposed roll design reveals that the solution can be used to produce railway axles with the desired geometry. This technique, however, requires relatively high loads and torques. To decrease the force parameters, the forming process was modified and ran in two operations. The first operation consists in forming the central step of the workpiece while the other one involves the formation of steps on the ends of the workpiece. The results of the new simulation show a significant decrease in the loads and torques, which is caused, among others, by reducing the nominal diameter of the rolls from 1600 mm to 1200 mm. The numerical findings can be used to design a rolling mill for producing rail axles.

show abstract

Section: New Trends In the Cwr Techniquementioning

confidence: 99%

A New Cross Wedge Rolling Process for Producing Rail Axles

Pater

Tomczak

2018

MATEC Web Conf.

View full text Add to dashboard Cite

show abstract

“…The forming process of the trapezoidal tooth thread shaft was analyzed in literature [6]. As the shape and the depth of the tooth of the top and bottom die increase, the tooth height and width increase gradually.…”

Section: Relationship Between Helix Angle and Rolling Forcementioning

confidence: 99%

“…The key issue in rolling the large diameter thread is poor control precision for tooth height and pitch. Many researchers studied the factors affecting the thread shape and obtained a number of laws and experiences [6][7]. However, the effect of the helix angle on the asymmetry of axial metal flow of the rolled pieces has not yet been studied.…”

Section: Introductionmentioning

confidence: 99%

Effect of Thread Helix Angle on the Axial Metal Flow of Cross Wedge Rolling Thread Shaft

Yan

Wang

Liu

et al. 2013

AMM

View full text Add to dashboard Cite

When rolling thread shaft in cross wedge rolling, forming quality of thread is affected by many process parameters such as the thread helix angle, which is a special and complex parameter. However, there is few study of the effect of the thread helix angle on thread shaft forming. In this paper how thread helix angle affects axial metal flow was analyzed from the perspective of rolling force and the forming process of thread shaft was simulated with different helix angles by the deform-3D software. Through the measurement of the point coordinates, the effect of the helix angle on the axial metal flow of rolled pieces was analyzed. Finally, the conclusion was obtained that helix angle causes the asymmetry of axial metal flow with small difference values for asymmetry and the axial metal flow of rolled pieces increases as the helix angle increases. The rolling thread segment can be ensured in the middle of rolled pieces by moving the blank a suitable distance in the reverse direction of the axial flow direction.

show abstract

“…Yan et al. 14–17 made detailed research on the roll cross wedge rolling thread. The forming mechanism and die design method were proposed.…”

Section: Introductionmentioning

confidence: 99%

Effect of rolling parameters on forming quality of flat cross wedge rolling thread shafts

Shao

Peng

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part E:

View full text Add to dashboard Cite

The flat cross wedge rolling is an advanced forming process, which is used to produce thread shafts. In this work, a finite element model of flat cross wedge rolling thread shafts was established by the DEFORM-3D, and the effect of the forming angle, spreading angle, helix angle and flank angle on forming quality are investigated. The research results show that the forming angle, spreading angle, helix angle have a significant influence on the position of the die wedge-in point. The angle designed wrongly makes the die wedge-in point unable to be aligned correctly, causing defects such as slipping in the process, repeated rolling of formed thread, thin or incomplete tooth shapes. The flank angle mainly makes an impact on the axial force. Reducing the right flank angle or increasing the left flank angle can effectively improve the imbalance of axial force to obtain high-quality thread shafts. Through the experiment of flat cross wedge rolling thread shafts, the data comparison demonstrates that the error of the external dimension of formed parts is small, proving the reliability of the rolling parameter selection.

show abstract

Effect of Blank Shape and Size on the Forming Quality of Thread Shaft Rolling in Cross Wedge Rolling

Cited by 4 publications

References 2 publications

A New Cross Wedge Rolling Process for Producing Rail Axles

A New Cross Wedge Rolling Process for Producing Rail Axles

Effect of Thread Helix Angle on the Axial Metal Flow of Cross Wedge Rolling Thread Shaft

Effect of rolling parameters on forming quality of flat cross wedge rolling thread shafts

Contact Info

Product

Resources

About