Finite element analysis and experimental study on roll-forming method in iso-wall thickness stator bushing of screw drilling

  • Xiaohua Zhu
  • Wen Ji


In this paper, roll-forming experiments are analyzed with the method of single-roller rotary feed (S-RRF). By exploring insufficiencies of the S-RRF, an improved method named multi-roller rotary feed (M-RRF) is proposed. The mechanical model of the roll-forming is set up. On the basis of the unit pressure differential equation by Karman, the rolling-force formula is obtained. Taking the stator bushing with the type of 5LZ73×7.0 as the research object, operation processes and rolling parameters of the M-RRF are investigated in reference to the finite element method (FEM). The influences of rolling speed, roller size, rolling temperature, and friction coefficient upon the rolling-force and the axial-force are studied. It is concluded that the rolling-force is the most sensitive to the temperature, and the axial-force is the most affected by the roller size. The effects of rolling temperature on residual stress are further investigated, and the evaluation index of the residual stress is established by exploring the distribution of stress. It is found that the fatigue strength of the stator bushing is improved as the radial working stress is counteracted by the radial compressive residual stress. It is also found that the forming efficiency of the M-RRF is m times than the S-RRF, and the forming quality is improved when billet pipe is compressed uniformly at the same time. Two-pass rolling can also improve the forming quality, but the forming stress in the secondary rolling is larger than that in the preforming as work-hardening phenomenon appears after one-pass rolling, and this phenomenon is more prominent in hot rolling.


Roll-forming Iso-wall thickness stator bushing Rolling-force Axial-force Rolling passes Residual stress 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. 1.
    Dong ZX, Wang K, Sun XW (2015) Capacity and faulty analysis of multi-lobe screw drill with iso-wall thickness stator. In: 2nd International Conference on Sensors Instrument and Information Technology (ICSIIT), Destech Publications, pp 27–28.Google Scholar
  2. 2.
    Hu ZQ, Zhen JJ, Feng ZM, Zshou SH (2014) Flexible rolling and stretch forming surface technology and numerical simulation. J Jilin U: Techno Ed 3:701–707Google Scholar
  3. 3.
    Lin ZC, Cheng YC (1995) An investigation of the effect of speeds of work rolls on rolling strip. J Eng Mater Technol 117(3):341–346CrossRefGoogle Scholar
  4. 4.
    Li MZ, Hu ZQ, Cai ZY, Gong XP (2007) Method of multipoint continuous forming for the freeform surface parts. J MECH ENG 43(12):155–159CrossRefGoogle Scholar
  5. 5.
    Yang F, Ren TY, Wang HB, Liu BX, Chen M (2017) Analysis of flow field for electrochemical machining metal screw pump stator. Int J Adv Manuf Technol 89:1317–1326CrossRefGoogle Scholar
  6. 6.
    Zhu XH, Shi CS, Tong H (2015) Optimizing loading path and die linetype of large length-to-diameter ratio metal stator screw lining hydroforming. J Cent South Univ 22:224–231CrossRefGoogle Scholar
  7. 7.
    Wang K, Guo MX, Sun XW (2013) Finite element analysis of rolling forming of uniform wall thickness PDM’s stator pipes. Mech Eng Autom 3:17–19Google Scholar
  8. 8.
    Morrow C A, Lovell M R, Li Q (2005) Determination of a critical forming parameter for the cross-wedge rolling of tubes. In: World Tribology Congress III. American Society of Mechanical Engineers, pp 819–820.Google Scholar
  9. 9.
    Wengfei P, Wenjing Y, Sijia J, Shu XD, Sun BS, Liu YZ, Zhan LH (2014) Analysis of cross wedge rolling of spiral shaft parts. Procedia Engineering 81:322–327CrossRefGoogle Scholar
  10. 10.
    Wu ZJ, Peng WF, Shu XD (2016) Influence of rolling temperature on interface properties of the cross wedge rolling of 42CrMo/Q235 laminated shaft. Int J Adv Manuf Technol: 1–10.Google Scholar
  11. 11.
    Ali MY, Pan J (2015) Residual stresses due to rigid cylinder indentation and rolling at a very high rolling load. J Manuf Sci Eng 137(5):051005CrossRefGoogle Scholar
  12. 12.
    Kim W, Kawai K, Koyama H, Miyazaki D (2007) Fatigue strength and residual stress of groove-rolled products. J Mater Process Technol 194(1):46–51CrossRefGoogle Scholar
  13. 13.
    Lim A, Castagne S, Wong CC (2016) Effect of deep cold rolling on residual stress distributions between the treated and untreated regions on Ti-6Al-4V alloy. J Manuf Sci Eng 138(11):111005CrossRefGoogle Scholar
  14. 14.
    Liu FC, Lei LP, Zeng P (2012) Surface rolling FE model for numerical simulation. J Plas Eng 19(2):17–21Google Scholar
  15. 15.
    Mehrabi R, Salimi M, Ziaei-Rad S (2015) Finite element analysis on chattering in cold rolling and comparison with experimental results. J Manuf Sci Eng 137(6):061013CrossRefGoogle Scholar
  16. 16.
    Keife H, Jonsäter T (1997) Influence of rolling speed upon friction in cold rolling of foils. J Tribol 119(2):349–357CrossRefGoogle Scholar
  17. 17.
    Liu X, Liewald M, Becker D (2009) Effects of rolling direction and lubricant on friction in sheet metal forming. J Tribol 131(4):042101CrossRefGoogle Scholar
  18. 18.
    Song YQ, Xu ZG, Zhao P, Liu Y (2006) Experimental analysis of roller burnishing process for metal plane. J Jilin U: Techno Ed 36(2):188–194Google Scholar
  19. 19.
    Sun JL, Yi MR, Sun Q, Lu MY (2014) Experimental investigation of the relationship between lubricants’ tribological properties and their lubricating performances in cold rolling. J Tribol 136(3):034502CrossRefGoogle Scholar
  20. 20.
    Shih CK, Hsu RQ, Hung C (2002) A study on seamless tube in the planetary rolling process. J Mater Process Technol 121(2):273–284CrossRefGoogle Scholar
  21. 21.
    Liu ZQ, Song JL, Li YT, Li XD (2011) Analysis and experimental study on the precision cold rolling process of involute spline. Chin J Mech Eng-en 47(14):32–38Google Scholar
  22. 22.
    Xu H, Wang X, Cui F, Zhang F (2009) Numerical simulation of cold rolling involute spline forming. In: 2009 International Conference on Mechatronics and Automation. IEEE, pp 3314–3318.Google Scholar
  23. 23.
    Cui MC, Zhao SD, Zhang DW, Chen C, Li YY (2016) Finite element analysis on axial-pushed incremental warm rolling process of spline shaft with 42CrMo steel and relevant improvement. Int J Adv Manuf Technol: 1–14.Google Scholar

Copyright information

© Springer-Verlag London 2017

Authors and Affiliations

  1. 1.Department of Mechatronic EngineeringSouthwest Petroleum UniversityChengduChina

Personalised recommendations