Skip to main content
SpringerLink
Log in

Experimental study on the axial-infeed incremental warm rolling process for spline shaft production

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this work, the axial-infeed incremental warm rolling process is introduced to the production of spline drive shaft with 42CrMo steel. To understand the role of warm forming temperature, the comparative experiments were conducted using the cold and warm axial-infeed incremental rolling process. Compared to the cold rolling process, the axial feed force is decreased 36.6% by warm rolling process. Meanwhile, the microstructure and hardness tests show that the results of the spline shafts formed by warm rolling are significantly better than those formed by cold rolling. Due to the effect of warm forming temperature, the formed spline shafts have obtained significant grain refinement, fiber texture formation, and hardness increase in the tooth profile area. Finally, the axial-infeed incremental warm rolling process has been used in actual production of semi-axis and the results are compared to the conventional production process. Through the pilot production, the productivity of spline shaft is increased 35.5% by the axial-infeed incremental warm rolling process, respecting to the conventional production process. The results in this work suggest that the axial-infeed incremental warm rolling process has great potential in mass production of spline shaft.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

References

  1. Guan WD (2010) Construction of automobile, 3rd edn. China Machine Press, Beijing In Chinese

    Google Scholar 

  2. Childs PRN (2004) Mechanical design, 2nd edn. Elsevier Butterworth-Heinemann, Oxford

    Google Scholar 

  3. Cui M, Zhao S, Chen C, Zhang D, Li Y (2017) Finite element modeling and analysis for the integration–rolling–extrusion process of spline shaft. Adv Mech Eng 9:1–11

    Google Scholar 

  4. Tschätsch H (2006) Metal forming practise. Translated by Koth A, Springer, Berlin

    Google Scholar 

  5. Sun H, Cui MC, Zhang Y, Zhao SD, Zhang DW, Deguchi Y (2018) Performance of AC servo axial-infeed incremental warm rolling equipment and simulated production of spline shafts. Int J Adv Manuf Technol 94:2089–2097

    Article  Google Scholar 

  6. Li YY, Zhao SD, Fan SQ, Yan GH (2013) Study on the material characteristic and process parameters of the open-die warm extrusion process of spline shaft with 42CrMo steel. J Alloys Comp 571:12–20

    Article  Google Scholar 

  7. Cui M, Deguchi Y, Wang Z, Fujita Y, Liu R, Shiou FJ, Zhao S (2018) Enhancement and stabilization of plasma using collinear long-short double-pulse laser-induced breakdown spectroscopy. Spectrochim Acta Part B 142:14–22

    Article  Google Scholar 

  8. Cui M, Deguchi Y, Yao C, Wang Z, Tanaka S, Zhang D (2020) Carbon detection in solid and liquid steel samples using ultraviolet long-short double pulse laser-induced breakdown spectroscopy. Spectrochim Acta Part B 167:105839

    Article  Google Scholar 

  9. Huang ZH, Fu PF (2001) Solution to the bulging problem in the open-die cold extrusion of a spline shaft and relevant photo plastic theoretical study. J Mater Process Technol 114:185–188

    Article  Google Scholar 

  10. Zou L, Xia JC, Wang XY, Hu GA (2003) Optimization of die profile for improving die life in the hot extrusion process. J Mater Process Technol 142:659–664

    Article  Google Scholar 

  11. Altinbalik T, Ayer Ö (2008) A theoretical and experimental study for forward extrusion of clover sections. Mater Des 29:1182–1189

    Article  Google Scholar 

  12. Cui FK, Wang XQ, Zhang FS, Xu HY, Quan JH, Li Y (2013) Metal flowing of involute spline cold roll-beating forming. Chin J Mech Eng 26:1056–1062

    Article  Google Scholar 

  13. Zhang DW, Zhao SD (2014) New method for forming shaft having thread and spline by rolling with round dies. Int J Adv Manuf Technol 70:1455–1462

    Article  Google Scholar 

  14. Zhang DW, Zhao SD, Wu SB, Zhang Q, Fan SQ, Li JX (2015) Phase characteristic between dies before rolling for thread and spline synchronous rolling process. Int J Adv Manuf Technol 81:513–528

    Article  Google Scholar 

  15. Zhang DW, Liu BK, Xu FF, Wang Q, Zhao SD (2019) A note on phase characteristic among rollers before thread or spline rolling. Int J Adv Manuf Technol 100:391–399

    Article  Google Scholar 

  16. Cui MC, Zhao SD, Zhang DW, Chen C, Fan SQ, Li YY (2017) Deformation mechanism and performance improvement of spline shaft with 42CrMo steel by axial-infeed incremental rolling process. Int J Adv Manuf Technol 88:2621–2630

    Article  Google Scholar 

  17. Cui MC, Zhao SD, Chen C, Zhang DW, Li YY (2016) Process parameter determination of the axial-infeed incremental rolling process of spline shaft. Int J Adv Manuf Technol 90:3001–3011

    Article  Google Scholar 

  18. Zhang DW, Yang H (2015) Analytical and numerical analyses of local loading forming process of T-shape component by using Coulomb, shear and hybrid friction models. Tribol Int 92:259–271

    Article  Google Scholar 

  19. Neugebauer R, Putz M, Hellfritzsch U (2007) Improved process design and quality for gear manufacturing with flat and round rolling. Ann CIRP 56:307–312

    Article  Google Scholar 

  20. Neugebauer R, Putz M, Hellfritzsch U (2007) Description of the interactions during gear rolling as a basis for a method for the prognosis of the attainable quality parameters. Prod Eng Res Devel 1:253–257

    Article  Google Scholar 

  21. Cui M, Zhao S, Chen C, Zhang DW, Li J, Li Y (2018) Study on warm forming effects of the axial-infeed incremental rolling process of spline shaft with 42CrMo steel. P I Mech Eng E-J Pro 232:555–565

    Article  Google Scholar 

  22. Cui M, Zhao S, Chen C, Zhang D (2018) The experimental study of axial in-feed incremental rolling process of spline shaft. J Mech Eng 54:199–204

    Article  Google Scholar 

  23. Lin YC, Chen MS, Zhong J (2008) Microstructural evolution in 42CrMo steel during compression at elevated temperatures. Mater Lett 62:2132–2135

    Article  Google Scholar 

  24. Lin YC, Chen MS, Zhong J (2008) Numerical simulation for stress/strain distribution and microstructural evolution in 42CrMo steel during hot upsetting process. Comput Mater Sci 43:1117–1122

    Article  Google Scholar 

  25. Li C, Li X, Wu Y, Zhang F, Huang H (2019) Deformation mechanism and force modelling of the grinding of YAG single crystals. Int J Mach Tool Manu 143:23–37

    Article  Google Scholar 

  26. Li C, Wu Y, Li X, Ma L, Zhang F, Huang H (2020) Deformation characteristics and surface generation modelling of crack-free grinding of GGG single crystals. J Mater Process Technol 279:116577

    Article  Google Scholar 

  27. Cui MC, Zhao SD, Zhang DW, Chen C, Li YY (2016) Finite element analysis on axial-infeed incremental warm rolling process of spline shaft with 42CrMo steel and relevant improvement. Int J Adv Manuf Technol 90:2477–2490

    Article  Google Scholar 

  28. Kong TF, Chan LC, Lee TC (2008) Numerical and experimental investigation of preform design in non-axisymmetric warm forming. Int J Adv Manuf Technol 37:908–919

    Article  Google Scholar 

Download references

Funding

This study was supported by the National Natural Science Foundation of China (No. 62005218), China Postdoctoral Science Foundation (No. 2019 M663823), Natural Science Basic Research Project of Shaanxi Province (No. 2019JM-466), Opening Foundation of Shaanxi University of Technology Shaanxi Key Laboratory of Industrial Automation (No. SLGPT2019KF01-19), and Talent Start-up Project of Shaanxi University of Technology (No. SLGQD1811).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shaanxi University of Technology, No.1 East 1st Ring Road, Hanzhong, 723001, Shaanxi, China

    Hongling Hou, Yongqiang Zhao & Minchao Cui

  2. Shaanxi Key Laboratory of Industrial Automation, Shaanxi University of Technology, Hanzhong, 723001, Shaanxi, China

    Yongqiang Zhao, Minchao Cui & Shengdun Zhao

  3. MIIT Key Laboratory of High Performance Manufacturing for Aero Engine, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Minchao Cui

Authors
  1. Hongling Hou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yongqiang Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Minchao Cui
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Shengdun Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Yongqiang Zhao or Minchao Cui.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Hou, H., Zhao, Y., Cui, M. et al. Experimental study on the axial-infeed incremental warm rolling process for spline shaft production. Int J Adv Manuf Technol 112, 2177–2186 (2021). https://doi.org/10.1007/s00170-020-06422-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-06422-3

Keywords

Search

Navigation