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Analysis of friction characteristics during the thread cold rolling process by using a novel single-tooth rolling friction test

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Abstract

The thread cold rolling process is an advanced produce for manufacturing thread parts. During this process, friction between the rolling die and the workpiece significantly influences the deformation process and the quality of the formed thread parts. However, material deformation and contact conditions between the rolling die and workpiece are complex, posing challenges to the study of friction during the deformation process. A single-tooth rolling friction test (STRFT) was proposed to investigate friction properties in the thread cold rolling process and surface morphology of the formed part. Moreover, the effects of friction on material flow behavior and stress distribution characteristics were investigated. Experiments were performed under various lubrication conditions, and finite element simulation was used to calibrate the friction factor. Rolling torque was significantly affected by the friction factor and regarded as the sensitive parameter. The friction factor m was determined as 0.16 under lubrication condition by comparing the torque during the test and the simulation. A larger friction factor increased deformation stress and decreased material flow speed. The bottom of the formed groove under larger deformation stress exhibited greater roughness and more surface defects than the flank.

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Data availability

The datasets used or analyzed during the current study are available from the author on reasonable request.

Abbreviations

K x :

Ratio of friction stress to tangential stress

K y :

Ratio of friction stress to radial stress

P x :

Tangential stress, MPa

P y :

Radial stress, MPa

R :

The radius of the arc on the addendum of the tooth, mm

k :

Shear yield strength, MPa

m :

Friction factor

p :

Normal stress, MPa

v :

Feed speed of rolling die, mm/s

v 0 :

Feed speed of die, mm/s

Ф :

Center angle, rad

\(\varepsilon\) :

Equivalent strain

\(\dot{\varepsilon }_{0}\) :

Reference strain rate, s−1

\(\dot{\varepsilon }\) :

Equivalent strain rate, s−1

θ :

A half of angle between the two flanks of tooth, rad

λ :

Sensitive coefficient

λ x , λ y :

Sensitive coefficient along tangential and radial direction

μ :

Coefficient of friction

σ:

Material flow stress, MPa

σx, σy :

Stress in x and y direction, MPa

τ :

Friction stress, MPa

φ :

Contact angle between the roller and workpiece, rad

ω 0 :

Rotating speed of workpiece, rpm

ω :

Rotating speed of the workpiece in STRFT, rpm

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Funding

This work was supported by the Shaanxi Province Key Research and Development Program of China [grant no. 2021GXLH-Z-049, 2020GY-168]; the Joint Fund for Aerospace Advanced Manufacturing Technology Research Key Program [grant no. U1937203] and the State Scholarship Fund from the China Scholarship Council (CSC).

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Authors and Affiliations

  1. School of Mechanical Engineering, Xi’an Jiaotong University, No.28 Xian Ning West Road, 710049, Xi’an, People’s Republic of China

    Shuowen Zhang, Dawei Zhang, Dazhou Liu, Yuanzhe Dong, Fan Li & Shengdun Zhao

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  1. Shuowen Zhang
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  2. Dawei Zhang
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  3. Dazhou Liu
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  4. Yuanzhe Dong
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  5. Fan Li
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  6. Shengdun Zhao
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Contributions

SZ: methodology, experiment, writing — original draft, writing — review and editing, visualization, and formal analysis. DZ: methodology. DL: writing — original draft. YD: supervision. FL: writing — review and editing. SZ: project administration and funding acquisition.

Corresponding authors

Correspondence to Dawei Zhang or Shengdun Zhao.

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Zhang, S., Zhang, D., Liu, D. et al. Analysis of friction characteristics during the thread cold rolling process by using a novel single-tooth rolling friction test. Int J Adv Manuf Technol 121, 5439–5449 (2022). https://doi.org/10.1007/s00170-022-09638-7

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