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Research and prospect of flexible forming theory and technology of hollow shaft by three-roll skew rolling

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Abstract

With the rapid development of high-end equipment in aviation, high-speed rail, and other fields, the requirements for the necessary shaft foundation parts on the equipment are more stringent. This has resulted in rapid development of the new generation of three-roll skew rolling (TRSR) flexible forming shaft part technology. It is an important issue to explore the theory and technology of TRSR flexible forming of hollow shaft and systematically expounding the flexible forming theory of TRSR of hollow axle. Therefore, this paper explores the feasibility of TRSR through the combination of theory and experiment and analyzes the formation mechanism as well as develop macro and micro uniformity law in order to clarify the quality control measures. In order to realize the low-cost forming of hollow axle with short process, the piercing-rolling compound forming (integrated forming of shape and inner hole of hollow axle) and the multi-roll skew tandem rolling technology for large section shrinkage shafts are innovated. The forming mechanism is verified through the simulation research. Based on the abovementioned research, it is concluded that skew-rolling composite integrated forming of large hollow shafts, multi-roll skew tandem rolling technology for large section shrinkage shafts, and the flexible forming process and equipment of digital TRSR is the future development direction of the TRSR flexible forming technology of hollow shaft. The results provide a theoretical basis and development direction for improving the precision short process, high efficiency, and high-quality manufacturing of high-end equipment shaft foundation.

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Funding

This study was funded by the National Natural Science Foundation of China (grant number: 51975301), the Natural Science Foundation of Zhejiang, China (grant number: LZ22E050002), and the Major Project of Science and Technology Innovation 2025 in Ningbo City, China (grant number: 2022Z064).

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Authors and Affiliations

  1. Faculty of Mechanical Engineering and Mechanics, Ningbo University, Ningbo, 315211, China

    Xuedao Shu, Jitai Wang, Caoqi Ye & Yingxiang Xia

  2. College of Mechanical and Automotive Engineering, Ningbo University of Technology, Ningbo, 315211, Zhejiang Province, China

    Song Zhang

  3. Zhejiang Key Laboratory of Part Rolling Forming Technology, Ningbo University, Ningbo, 315211, China

    Xuedao Shu, Song Zhang, Jitai Wang, Caoqi Ye & Yingxiang Xia

  4. Department of Mechanical Engineering, University of Birmingham, Birmingham, B15 2TT, UK

    Chang Shu & Khamis Essa

  5. Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka Str. 36, 20-618, Lublin, Poland

    Zbigniew Pater

Authors
  1. Xuedao Shu
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  2. Song Zhang
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  3. Chang Shu
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  4. Jitai Wang
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  5. Caoqi Ye
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  6. Yingxiang Xia
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  7. Khamis Essa
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  8. Zbigniew Pater
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Contributions

Shu Xuedao made the experimental plans, performed data processing, and performed finite element simulations. Zhang Song and Shu Chang wrote the paper. Shu Xuedao and Zhang Song determined the direction of the paper and the purpose of the experiment. Wang Jitai, Ye Caoqi, and Xia Yingxiang assisted to complete the experiment and helped revise the paper. Essa Khamis and Pater Zbigniew assisted to complete the experiment and check the literature. All authors read and approved the final manuscript.

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Correspondence to Xuedao Shu.

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Shu, X., Zhang, S., Shu, C. et al. Research and prospect of flexible forming theory and technology of hollow shaft by three-roll skew rolling. Int J Adv Manuf Technol 123, 689–707 (2022). https://doi.org/10.1007/s00170-022-10242-y

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  • DOI: https://doi.org/10.1007/s00170-022-10242-y

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