Feasibility Study on Forming Hollow Axle with Multi-Wedge Synchrostep by Cross Wedge Rolling

Sun, Bo; Zeng, Xue Lei; Shu, Xinyu; Wen, Peng; Sun, Pei Ting

doi:10.4028/www.scientific.net/amm.201-202.673

Cited by 24 publications

(16 citation statements)

References 2 publications

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“…It happens because this method has numerous advantages (large efficiency, relatively low material consumption, environment friendly method), and its main disadvantage (complex designing process of wedge tools) is successively eliminated due to application of possibilities provided by computer modeling. Aiming at increasing efficiency of the CWR process, a new variant of this process was worked out, that is multi wedge cross rolling (MWCR), in which a part is formed by a few pairs of wedges at the same time [3][4][5][6][7]. In the MWCR process tools length was shortened, yet it resulted in their more complicated shape (extreme wedge construction should consider a product elongation due to central wedges acting) and a considerable increase of forces and forming moments, which values very often exceed the permitted scopes of machines used in industrial conditions.…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the Skew Rolling Process for Rail Axles

Pater¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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The paper describes a new method for producing stepped rail axles. The method is based on the skew rolling process. With this method, the product is formed by three tapered rolls located every 120• on the perimeter of the billet. Positioned askew to the centerline of the billet, the rolls rotate in the same direction and with the same velocity. At the same time, they get closer together or go apart depending on the desired cross sectional reduction of an axle step. In addition, the workpiece is shifted lengthwise relative to the rolls by the translational motion of the workpiece-holding chuck. In order to verify the designed method for producing rail axles, a series of numerical simulations were performed using the Simufact.Forming v.12 simulation software. The numerical modeling enabled the determination of maps of the effective strain and temperature in the finished product as well as variations in the loads and torques during rolling. The numerical results unambiguously confirm that the skew rolling method can be applied to form parts of considerable dimensions (the modeled axles had a length of 2146 mm and their maximum diameter was 202 mm).Keywords: Skew rolling, rail axle, FEM W artykule opisano metodę wytwarzania stopniowanej osi wagonowej bazującą na procesie walcowania skośnego. W metodzie tej wyrób kształtowany jest za pomocą trzech rolek stożkowych, rozmieszczonych na obwodzie wsadu co 120• . Rolki te ustawione są skośnie względem osi wsadu, a w trakcie kształtowania obracają się z jednakową prędkością w tę sa-mą stronę oraz jednocześnie zsuwają lub rozsuwają się -w zależności od redukcji przekroju poprzecznego kształtowanego stopnia osi. Dodatkowo, wyrób kształtowany przesuwany jest wzdłużnie względem rolek, w wyniku ruchu postępowego uchwytu utwierdzającego jeden z jego końców. Sprawdzenia poprawności założonej koncepcji kształtowania osi wagonowej dokonano w drodze symulacji numerycznej wykonanej w programie Simufact.Forming v.12. W efekcie wykonanych obliczeń uzyskano mapy intensywności odkształcenia i temperatury w ukształtowanym wyrobie oraz wyznaczono przebiegi sił i momentów w trakcie walcowania. Jednoznacznie potwierdzono możliwość kształtowania wyrobów o dużych gabarytach (długość osi wynosi 2146 mm, a jej średnica maksymalna 202 mm) metodą walcowania skośnego.

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Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the Skew Rolling Process for Rail Axles

Pater¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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“…The research and development works conducted so far have concentrated on the application of this method for producing automotive axle shafts [2,[5][6][7], stepped shafts [4,8] as well as railway axles, both solid [9] and hollow [3]. In addition to this, the method can be used for forming several short parts at one time.…”

Section: Survey Of the Research On Mwcrmentioning

confidence: 99%

Analysis of a cross wedge rolling process for producing drive shafts

Pater

Tomczak

Bulzak

2016

Int J Adv Manuf Technol

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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.

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“…Such an approach requires advanced plastic-forming technology to be developed. This technology would allow the hollow element to be manufactured from both filled and hollow (commercial pipes) billet [5,6,7]. The majority of the currently applied plastic-forming technologies for hollow products and semi-finished products is very complex and requires the use of expensive machines.…”

Section: Introductionmentioning

confidence: 99%

Limits of the Process of Rotational Compression of Hollow Stepped Shafts

2019

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This article presents the results of theoretical–experimental testing of the process of rotational compression of hollow stepped shafts. The advantages of the technology and the potential area of its application were discussed. Further on, the limits of the rotational compression technology, preventing the manufacturing of high-quality products, were presented. The research was conducted on the basis of numerical modelling using the finite element method in Simufact Forming, as well as the results of experimental tests performed in a forging machine for rotational compression. On the basis of the results obtained, it can be stated that the process of rotational compression of hollow stepped shafts can be hindered by the following phenomena: uncontrolled slip, deformation of the semi-finished product wall, twisting of the formed steps, material cracking, and deformation of the cross-section of the formed steps. The possibility of those hindrances occurring depends heavily on the assumed technological parameters of the process. For this reason, knowledge of the cause of occurrence of those limitations is vital for the development of the technology and the choice of the process parameters.

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Feasibility Study on Forming Hollow Axle with Multi-Wedge Synchrostep by Cross Wedge Rolling

Cited by 24 publications

References 2 publications

Numerical Analysis of the Skew Rolling Process for Rail Axles

Numerical Analysis of the Skew Rolling Process for Rail Axles

Analysis of a cross wedge rolling process for producing drive shafts

Limits of the Process of Rotational Compression of Hollow Stepped Shafts

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