Multi-wedge Cross Wedge Rolling Process of 42CrMo4 Large and Long Hollow Shaft

Peng, Wenfei; Zheng, Shuhua; Chiu, Yi-Jui; Shu, Xuedao; Zhan, Lihua

doi:10.1016/s1875-5372(16)30084-4

Cited by 42 publications

(20 citation statements)

References 3 publications

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“…375 mm) using tools, the maximum length of which could not exceed 1250 mm (their maximum length was due to the machine design). For that reason, we decided to employ multi-wedge rolling that is also used for producing elongated parts such as stepped axes and shafts [16][17][18][19]. To this end, we designed tools with three wedges described by the same forming angles set to 25°.…”

Section: Numerical Modeling Of the Proposed Process For Forming Ballsmentioning

confidence: 99%

An innovative method for producing balls from scrap rail heads

Pater

Tomczak

Bulzak

et al. 2018

Int J Adv Manuf Technol

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The paper describes an innovative technological solution for producing balls from scrap rail heads. The proposed method consists in performing the following operations: the side pressing of a rail head to increase shape compactness, a process for forming a cylindrical rod by cross-wedge rolling (CWR), a CWR process for producing balls that have a diameter which is by 35% larger than that of the billet, quenching of the produced balls. Tools for the above manufacturing operations are designed, and numerical simulations are performed to verify whether the assumptions of the proposed technique are correct. A flat-wedge reversing mill is designed and constructed that enables performing the two abovementioned rolling operations without idle running, which makes the design innovative on a global scale. The implementation of the proposed method would enable producing balls for grinding media used in ball mills.

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Section: Numerical Modeling Of the Proposed Process For Forming Ballsmentioning

confidence: 99%

An innovative method for producing balls from scrap rail heads

Pater

Tomczak

Bulzak

et al. 2018

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…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%

“…Nonetheless, not only are these methods far from being efficient, they can lack accuracy (open die forging processes). For this reason, new methods for producing rail axles are sought, with emphasis on techniques based on skew rolling [2] and cross wedge rolling (CWR) processes [1,[3][4][5].…”

Section: Introductionmentioning

confidence: 99%

A New Cross Wedge Rolling Process for Producing Rail Axles

Pater

Tomczak

2018

MATEC Web Conf.

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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.

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“…CWR is usually applied in the metal forming industry for the manufacture of elongated products, such as stepped shafts [6][7][8][9], balls [10], and preforms of forging [11][12][13][14][15][16][17].…”

Section: Working Principle Of Cross Wedge Rollingmentioning

confidence: 99%

Research and industrialization of near-net rolling technology used in shaft parts

2018

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Shaft part rolling is an efficient and green nearnet shaping technology offering many advantages, including high production efficiency, high material utilization rate, high product quality, and excellent production environment. In this paper, the features of shaft part rolling are introduced along with the working principles of two main shaft part rolling technologies, namely, cross wedge rolling (CWR) and skew rolling (SR). In relation to this technology, some R&D achievements gained by the University of Science and Technology Beijing are summarized. Finally, the latest developments in shaft part rolling are presented, including SR steel balls, precise forming of camshaft blank by CWR, SR phosphorous copper balls at room temperature, and CWR hollow axle sleeve. Although the shaft part rolling technology has been widely used in China, it only accounts for about 15% of applicable parts at present. Nevertheless, this technology has broad application prospects.

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Multi-wedge Cross Wedge Rolling Process of 42CrMo4 Large and Long Hollow Shaft

Cited by 42 publications

References 3 publications

An innovative method for producing balls from scrap rail heads

An innovative method for producing balls from scrap rail heads

A New Cross Wedge Rolling Process for Producing Rail Axles

Research and industrialization of near-net rolling technology used in shaft parts

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