Modified Cross-Wedge Rolling for Creating Hollow Shafts

Landgrebe, Dirk; Steger, Jürgen; Böhmichen, Uwe; Bergmann, Markus

doi:10.1016/j.promfg.2018.02.094

Cited by 13 publications

(3 citation statements)

References 4 publications

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“…In the actual rolling process, the roll speed will fluctuate at the beginning and the end of the rolling process. Roll speed is not considered in this study [32]. (4) The friction model is set as the shear model, and the friction coefficient is set as a constant value.…”

Section: For Peer Review 4 Of 22mentioning

confidence: 99%

Numerical Analysis and Parameter Optimization of Wear Characteristics of Titanium Alloy Cross Wedge Rolling Die

Peng

Huang

et al. 2021

Metals

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Cross wedge rolling has the advantages of high production efficiency, good product quality, high material utilization, environmental protection, and low cost. It is one of the best processing methods for producing shaft blanks. In this paper, a cross wedge rolling die of TC4 titanium alloy is studied. Based on the Archard wear model, a modified model suitable for cross wedge rolling die wear analysis is derived through finite element simulation. Then, the modified Archard wear model is imported into Deform-3D software for finite element analysis. Orthogonal experimental design is used to combine and analyze different process parameters. Finally, the beetle antennae search (BAS)-genetic algorithm (GA)-back propagation neural network (BPNN) algorithm is used to predict the degree of die wear and to optimize the simulation parameters, which can acquire the process parameters that have the least impact on die wear. The results show that the wear distributions of cross wedge rolling tools is uneven. In general, the most serious areas are basically concentrated in the wedge-shaped inclined plane and rectangular edge lines. The reason is that the tangential force and radial force received by the die are relatively large, which leads to increased wear. Moreover, the temperature change is most severe on the wedge-shaped ridge line. When in contact with the workpiece, the temperature rises sharply, which makes the local temperature rise, the mold hardness decrease, and the wear accelerate. Through response surface method (RSM) analysis, it is concluded that the deformation temperature is the main factor affecting wear depth, followed by the forming angle, and that there is an interaction between the two factors. Finally, the feasibility of the BAS-GA-BP algorithm for optimizing the wear behavior of dies is verified, which provides a new process parameter optimization method for the problem of die wear in the cross wedge rolling process.

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Section: For Peer Review 4 Of 22mentioning

confidence: 99%

Numerical Analysis and Parameter Optimization of Wear Characteristics of Titanium Alloy Cross Wedge Rolling Die

Peng

Huang

et al. 2021

Metals

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“…Neugebauer et al [12] proposed two ways to control the movements of mandrel: fixed or freedom mandrel. Landgrebe et al [13] modified the typical CWR via adding a drilling mandrel, therefore a hollow shaft can be directly rolled from a solid billet. Shen et al [14,15] used a compensated mandrel to produce hollow shafts with a variable inner diameter.…”

Section: Introductionmentioning

confidence: 99%

Producing hollow shafts in a new horizontal mill by novel flat-knifing cross-wedge rolling with single guide

Lin

Wang

Shen

et al. 2021

Int J Adv Manuf Technol

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To meet the requirement of lightweight, there are increasing solid shafts being designed to be hollow in transportation industry. In this study, a novel method of flatknifing cross-wedge rolling (FCWR) with single guide is proposed including a modified roller, a horizontal mill and a single-guide structure, and its key problems are studied by numerical simulations and experimental tests. A mathematical model of FCWR roller is established, which reveals the wedge length of rollers is effectively reduced by modifying knifing wedge from normalized roller. Further, a horizontal multifunctional mill is invented and constructed to carry out the FCWR experiment with single guide. According to the results from the numerical simulations and corresponding experiments, it is observed that the typical defects of hole expansion and knifing groove are absolutely avoided because the improved flat-knifing wedge produces a radial force to shrink the inner hole and avoid the deformation concentration of the outer surface during knifing stage. Moreover, the single guide rolling performed in the horizontal mill efficiently improve rolling stability because the workpiece is restricted into a smaller workspace. To the authors' knowledge, all these integrated improvements of FCWR roller, single guide rolling and horizontal mill are innovative, which are of great engineering significance to manufacture hollow shafts on account of the advantages of avoiding forming defect, reducing roller diameter, improving rolling stability and simplifying mill structure.

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“…The process consists in reducing the diameter of a tube by three rotating tools; the tools are stepped rollers moving toward the axis of the workpiece. Parts produced in this way can be effectively used in aircraft structures or automotive and engineering parts, and their manufacturing is easier and cheaper than other methods [ 15 , 16 , 17 , 18 ]. This study proposes the use of rotary compression for producing more complex parts that have not only circular-section steps, but also gears [ 19 , 20 ] and worms [ 21 ].…”

Section: Introductionmentioning

confidence: 99%

A Rotary Compression Process for Producing Hollow Gear Shafts

et al. 2020

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This paper presents selected numerical and experimental results of a study investigating the process of forming hollow stepped gear shafts from tubes by rotary compression. The objective of the study was to determine whether the rotary compression process is an effective method of producing hollow stepped gear shafts and to identify limitations of this manufacturing method. A theoretical analysis involved the numerical modeling of the proposed process by the finite element method (FEM). 3D simulations were performed using the commercial simulation software package Simufact Forming. The analysis involved examining the material flow pattern along with thermal and force parameters of the process. The FEM results were verified with experimental tests conducted under laboratory conditions. The experiments were performed on a machine specially designed for the rotary compression of hollow parts. Results demonstrate that it is difficult to form a stepped gear shaft in one operation. For this reason, such parts should be formed in two operations. The first operation involves the forming of a hollow stepped shaft by rotary compression, while in the second operation, a gear is formed on one of the steps of the shaft.

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Modified Cross-Wedge Rolling for Creating Hollow Shafts

Cited by 13 publications

References 4 publications

Numerical Analysis and Parameter Optimization of Wear Characteristics of Titanium Alloy Cross Wedge Rolling Die

Numerical Analysis and Parameter Optimization of Wear Characteristics of Titanium Alloy Cross Wedge Rolling Die

Producing hollow shafts in a new horizontal mill by novel flat-knifing cross-wedge rolling with single guide

A Rotary Compression Process for Producing Hollow Gear Shafts

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