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Study on forming quality of three-roll skew rolling hollow axle

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Abstract

To optimize the wall thickness quality of three-roll skew rolling (TRSR) hollow axle, this paper explores the wall thickness quality from the perspective of forming mechanism and test design analysis. First, the finite element model of TRSR hollow axle was established based on SIMUFACT software. Second, the evolution characteristics of workpiece wall thickness under various initial wall thickness conditions were found by single factor test. Third, based on the metal flow velocity, the formation mechanism of wall thickness at different positions of the workpiece is discussed, and the causes of various wall thickness defects are found. Fourth, the wall thickness quality evaluation index was proposed and the orthogonal test was carried out. The relationship between process parameters and wall thickness quality was obtained. Fifth, a method of using irregular billets was proposed to improve wall thickness quality. The results indicate that the diversity of initial wall thickness of the workpiece can lead to two phenomena: wall thinning and wall thickening. A larger wall thickness will result in thinning of the wall thickness, while a smaller wall thickness will result in thickening of the wall thickness. The method of adjusting process parameters has limited impact on improving wall thickness quality. The method of using irregular billets can greatly improve the wall thickness quality of the hollow shaft.

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Funding

This study was supported by the National Natural Science Foundation of China (Grant Number: 51975301), the National Natural Science Foundation of China Youth Project (Grant Number: 52205403), 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, 2022Z009, 2022Z015).

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Authors and Affiliations

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

    Jitai Wang, Xuedao Shu, Caoqi Ye, Zixuan Li, Shuxin Li, Haijie Xu, Ying Wang, Yimin Deng & Qian Chen

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  1. Jitai Wang
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  2. Xuedao Shu
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  3. Caoqi Ye
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  4. Zixuan Li
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  5. Shuxin Li
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  6. Haijie Xu
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  7. Ying Wang
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  8. Yimin Deng
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  9. Qian Chen
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Contributions

Conceptualization: J.T. W. and X.D. S.; modeling and simulation: J.T. W. and C.Q. Y.; data analysis: J.T. W and Z.X. L; data interpretation: J.T. W and S.X. L.; experiment: J.T. W, Y. W, Y.M. D., and Q. C; writing—original draft preparation: J.T. W; writing—review and editing: X.D. S. and H.J. X. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Xuedao Shu.

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Wang, J., Shu, X., Ye, C. et al. Study on forming quality of three-roll skew rolling hollow axle. Int J Adv Manuf Technol 128, 1089–1100 (2023). https://doi.org/10.1007/s00170-023-11893-1

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