Effects of Die Tooth Profile on Forming Helical Tooth Shaft in Cross Wedge Rolling

Abstract

The study on forming helical tooth shaft processes in cross wedge rolling can contribute to the advantages of material-saving and efficient. Die tooth profile is an important process parameter of cross wedge rolling helical tooth shaft. Three kinds of forming process of die helical teeth were simulated by DEFORM-3D finite element analysis software to analyze three different die helical tooth. According to the tooth forming characteristics, the effects of three kinds of die tooth profile on forming of a polled piece were analyzed. When rolling a polled piece using the die with the same addendum width, it is convenient for die processing and the effect of polled piece forming is better; when using the die with the narrow front and gradually wider rear, the defects of uneven tooth bottom and larger pitch may happen. The rolling experiment was made by using the die with the same width at the tooth bottom. The results are in good agreement with the simulation. Therefore, we should use the die with unchanged addendum width, tooth height and the sidewall proportional increased when designing the die.

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

“…The effect law of die process parameters in rolling thread shafts in cross wedge rolling was investigated in literature [6]. Because the helix angle as an important process parameter in rolling thread shafts varies instantly during the rolling process, in order to minimize the influence of the helix angle while considering the convenience for process, the variable helix angle of the die was selected.…”

“…Because the current die cavity of cross wedge rolling is closed in the middle section and open on both sides, the metal flows outward easily along the direction of the minimum force in the metal forming process and thus the tooth height becomes smaller, the pitch becomes larger on both sides of the thread portion [5]. The forming law was analyzed through the forming process parameters of die in literature [6], which tried to solve the problem of forming defects, but only with some effects. Based on the metal flow of forming thread tooth, by modifying the blank shape and size, the effect law of the blank shape on the height and pitch of the teeth were studied in this paper, and ultimately the reasonable sizes of the blank were obtained.…”

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

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

Research on defects and control method based on thread shaft forming

“…The cross wedge rolling is the advanced manufacturing technology with advantages of saving materials, high efficiency and protecting environment [2] [3]. Many experts and scholars have conducted in-depth research for the technology and gained valuable research results [4][5] [6], and many technology of rolling shafts are applied to the industrial production [7] [8]. In summary, rolling thread shaft by cross wedge rolling has good prospect.…”