Influence Analysis of Block Wedge on Rolled-Piece End Quality in Cross Wedge Rolling

Shu, Xinyu; Wei, Xin Hong; Chen, Le Ping

doi:10.4028/www.scientific.net/amm.101-102.1055

Cited by 5 publications

(3 citation statements)

References 2 publications

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“…The first method was to constrain metal flow in the axial direction by means of side guides. This solution was described in studies by Shu et al [10] and Pater et al [11]. The second method involved providing the tool with a specially designed wedge block.…”

Section: Introductionmentioning

confidence: 99%

Multi-Variant Analysis of the Cross Wedge Rolling Process for Producing Railcar Axles

Pater,

Tomczak,

Bulzak

2023

Adv. Sci. Technol. Res. J.

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This study investigates the cross wedge rolling (CWR) process for manufacturing a rail axle in a scale of 1:6. Three cases of the rolling process are modelled numerically: standard rolling, wasteless rolling and rolling from a preform. The rolling cases under analysis are compared in terms of material and energy consumption, forming loads as well as propensity to internal and external defect formation. Using the Cockcroft-Latham criterion and the limits of this criterion determined by the rotary compression test, an assessment was made of the propensity of the material to fracture during the rolling processes analysed. Based on numerical results, standard CWR is selected for experimental verification. Obtained experimental results confirm that CWR is an effective method for producing railcar axles that are free from both internal and external defects. The experimental and numerical results obtained confirm that cross wedge rolling technology can be successfully used under industrial conditions for the production of long axles or shafts.

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Section: Introductionmentioning

confidence: 99%

Multi-Variant Analysis of the Cross Wedge Rolling Process for Producing Railcar Axles

Pater,

Tomczak,

Bulzak

2023

Adv. Sci. Technol. Res. J.

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“…Zhenhai Ma [ 10 ] studied the influence laws of process parameters on the volume of stub bars, and put forward the theory that the concave size would decrease with the increasing of the forming angle and the constant size of the rolling piece’s end, and would increase with the increasing of the spreading angle and deformation quantity. Wangming Zu and Xinhong Wei [ 11 , 12 ] erected side wedges on the die in order to restrain the flow of the surface metal at the rolling end, thus decreasing the size of the concave. Wenwei Gong [ 13 ] put forward the method to design press blocks on the die in order to restrain the flow of the surface metal of the rolling piece, thus constraining the formation of concaves.…”

Section: Introductionmentioning

confidence: 99%

Study on Near-Net Forming Technology for Stepped Shaft by Cross-Wedge Rolling Based on Variable Cone Angle Billets

Han

Shu

2018

Materials

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Considering problems about concaves at the stepped shaft ends, this paper established the plastic flow kinetic theories about metal deforming during the cross-wedge rolling (CWR) process. By means of the DEFORM-3D finite element software and the point tracing method, the forming process of stepped shafts and the forming mechanism of concaves at shaft ends were studied. Based on the forming features of stepped shafts, rolling pieces were designed using variable cone angle billets. Single-factor tests were conducted to analyze the influence law of the shape parameters of billet with variable cone angle on end concaves, and rolling experiments were performed for verification. According to the results, during the rolling process of stepped shafts, concaves will come into being in stages, and the increasing tendency of its depth is due to the wave mode, the parameters of cone angle α, the first cone section length n. Furthermore, the total cone section length m has an increasingly weaker influence on the end concaves. Specifically, cone angle α has the most significant influence on the quality of shaft ends, which is about twice the influence of the total cone section length m. The concave depth will decrease at the beginning, and then increase with the increasing of the cone angle α and the first cone section length n, and it will decrease with the increasing of the total cone section length m. Finite element numerical analysis results are perfectly consistent with experimental results, with the error ratio being lower than 5%. The results provide a reliable theoretical basis for effectively disposing of end concave problems during CWR, rationally confirming the shape parameters of billets with a variable cone angle, improving the quality of stepped shaft ends, and realizing the near-net forming process of cross-wedge rolling without a stub bar.

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“…This effect can be achieved by making special wedge-shaped grooves on the tools (for restraining the material's surface flow) or by providing the tools with special side guides to totally prevent an axial flow of the material [26,27]. The application of these solutions reduces the size of cavities and ensures a considerable increase in the cross-sectional reduction in the workpiece in one tool pass [28].…”

Section: Introductionmentioning

confidence: 99%

Cavity formation in cross-wedge rolling processes

Pater

Tomczak

Bulzak

2018

J. Iron Steel Res. Int.

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The problem of end-face cavity formation in parts produced by cross-wedge rolling was studied in order to reduce material consumption. The cavity depth was measured by the displacement method. Twenty-one different cases of rolling were analysed by finite element method to determine the effects of process parameters such as the wedge tool angle, the temperature of material, the tool velocity and the reduction ratio on the depth of end-face cavities. Relationships between these parameters are examined in order to establish dependencies enabling quick and simple selection of a concavity allowance in order to remove the cavities. The equations for calculating the concavity allowance were verified in an experimental process for manufacturing ball pins with the use of flat tools. Rolling tests were performed using a billet with its length selected in compliance with the established dependencies. The experimental results demonstrate that the proposed solution is a viable method for end-face cavity removal.

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Influence Analysis of Block Wedge on Rolled-Piece End Quality in Cross Wedge Rolling

Cited by 5 publications

References 2 publications

Multi-Variant Analysis of the Cross Wedge Rolling Process for Producing Railcar Axles

Multi-Variant Analysis of the Cross Wedge Rolling Process for Producing Railcar Axles

Study on Near-Net Forming Technology for Stepped Shaft by Cross-Wedge Rolling Based on Variable Cone Angle Billets

Cavity formation in cross-wedge rolling processes

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