Overview of the Research on Roll Forging Processes

Tofil, Arkadiusz; Pater, Z.

doi:10.12913/22998624/70645

Cited by 11 publications

(6 citation statements)

References 108 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In order to achieve the technical objective of single guide rolling, a laboratory mill with a horizontal structure is indispensable. Up to now, the traditional CWR mills commonly have a vertical structure [4,5,22], which apparently cannot meet the requirement of this study.…”

Section: New Type Of Horizontal Multifunctional Millmentioning

confidence: 98%

“…Cross wedge rolling (CWR), a near-net shape metal manufacturing process with high production efficiency and low material consumption, has an extensive application in solid shafts including large-elongated parts (e.g., automobile camshafts, stepped shafts) and die-forging preforms (e.g., engine valves, connecting rods, double-ended spanners) as reviewed by Hu et al [4] and Pater et al [5]. Hu et al [4] pointed out they have established more than 300 production lines worldwide with an estimated production value of more than $200 million per year, and highlighted that the weight of CWR products has over 400,000 tons with an amount of 2 billion pieces per year in China.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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

View full text Add to dashboard Cite

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.

show abstract

Section: New Type Of Horizontal Multifunctional Millmentioning

confidence: 98%

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

View full text Add to dashboard Cite

show abstract

“…The point contact between tools and workpiece makes job to move along the plane perpendicular to axis of the work;  Helical rolling: the work piece is subjected to both translational and rotary motions where rolls also rotating at same direction. The points if contact between work and tools results in central motion [4]. Roll forging is now used to make reductions in crosssections and distribution of a metal of billet which reduces extensive work using forging hammers or presses [20].…”

Section: ) Roll Forging Processmentioning

confidence: 99%

Review and Prospect of Process Research on Large Forgings

2022

JRSE

View full text Add to dashboard Cite

Forging is one of the famous and primitive sorts of manufacturing processes. The history of forging dates to even earlier than 4000BC which involved a couple of hand tools and anvils called smith forging which relied on hits and trials requiring huge skills and high precisions. These days, the forging tools, operations, and methods are automated and power-driven. In this research, the recent developments and advancements in various forging processes are analyzed by reading various research papers and journals of the last two decades. The papers were evaluated for substantial upgrades in precision and technologies. The use of power hammers, artificial intelligence such as the use of robotics, computer numerical controls (CNCs) has made forging a drastic shift towards mechanization. This review will help to highlight the recent progress of the forging processes and act as an easy guide to encapsulate the recent optimization of various processes.

show abstract

“…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

Self Cite

View full text Add to dashboard Cite

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.

show abstract

Overview of the Research on Roll Forging Processes

Cited by 11 publications

References 108 publications

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

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

Review and Prospect of Process Research on Large Forgings

A Rotary Compression Process for Producing Hollow Gear Shafts

Contact Info

Product

Resources

About