Skip to main content
SpringerLink
Log in

Study on the deformation mechanism for forming shafts without concavity during the near-net forming cross wedge rolling process

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

Abstract

In this paper, a simulation model for two-roll cross wedge rolling (CWR) was presented to investigate the deformation mechanism for forming shafts without concavity by using the finite element method. Based on the simulation results, the reason for concavity in both sides of the rolled piece in the CWR process was analyzed in detail, and a method to implement the CWR process without loss of material was brought forward by billet compensation. In addition, the influence of the main process parameters on the concavity depth of the workpiece with a tapered or circular-arc end was compared and ascertained. The study results show that the concavity depth is in direct proportion to the cone angle, but in inverse proportion to the central angle, and the concavity can be improved with larger area reduction and mill length under the two profiled ends. Subsequently, the feasibility of using profiled billets to effectively control the concavity was verified via the rolling experiments.

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

Similar content being viewed by others

References

  1. Yan HJ, Mao HE, Wang LJ, Liu YZ, Liu JP, Hu ZH (2012) Study on metal flow law in cross wedge rolling of trapezoidal helical tooth shaft. J Plastic Eng 19(5):20–24

    Google Scholar 

  2. Zhao R, Zhang KS, Hu ZH (2012) Different equations for solving shaping curve of inside right-angle steps in cross wedge rolling. Forg Stamp Technol 37(4):70–74 (in Chinese)

    Google Scholar 

  3. Yang CP, Hu ZH (2016) Research on the ovality of hollow shafts in cross wedge rolling with mandrel. Int J Adv Manuf Technol 83:67–76

    Article  Google Scholar 

  4. Yang YM, Xiao B, Zhao J (2013) Feasibility study on cross wedge rolling forming for jaw crusher eccentric shafts. Hot Work Technol 42(15):115–121 (in Chinese)

    Google Scholar 

  5. Yan HJ, Ma SB, Han PB, He XX, Liu JP, Hu ZH (2014) Effect of process parameters on core quality of thread shaft rolling in cross wedge rolling. J Plastic Eng 39(3):62–66

    Google Scholar 

  6. Li N, Wang ZX, Yang KJ, Yu XL, Chen WZ (2015) Analysis on forming defects during asymmetric cross wedge rolling and determination of die parameters. J Mater Sci Eng 33(2):263–267

    Article  Google Scholar 

  7. Huang HB, Chen X, Fan BB, Jin YC, Shu XD (2015) Initial billet temperature influence and location investigation on tool wear in cross wedge rolling. Int J Adv Manuf Technol 79:1545–1556

    Article  Google Scholar 

  8. Zhou J, Xiao C, Yu YY, Jia Z (2013) Influence of tool parameters on tool wear in two-roll cross-wedge rolling. Int J Adv Manuf Technol 65:745–753

    Article  Google Scholar 

  9. Wang MH, Xiang D, Xiao C, Zhou J, Jia Z (2012) Influence of cooling condition of tools on central deformation of workpiece and tool wear in cross wedge rolling. Int J Adv Manuf Technol 59:473–482

    Article  Google Scholar 

  10. Liu YB, Chen WL, Zheng MY (2015) Forging process of improvement on wedge rolling with large cross-sectional area shrinkage. J Netshape Form Eng 7(4):11–16 (in Chinese)

    Google Scholar 

  11. Li Q, Lovell MR (2004) The establishment of a failure criterion in cross wedge rolling. Int J Adv Manuf Technol 24:180–189

    Google Scholar 

  12. Li N, Ge XM, Yang XY, Wang ZX (2015) Combined application of cross wedge rolling and die forging technology in shaft parts production. Hot Work Technol 44(17):115–117 (in Chinese)

    Google Scholar 

  13. Ji HC, Liu JP, Wang BY, Zhang ZR, Zhang T, Hu Z (2015) Numerical analysis and experiment on cross wedge rolling and forging for engine valves. J Mater Process Technol 221:233–242

    Article  Google Scholar 

  14. Ma ZH, Yang CP, Hu ZH (2002) Study on effect factors of end concavity in cross wedge rolling. Forg Stamp Technol 27(1):29–31 (in Chinese)

    Google Scholar 

  15. Liu GH, Jiang Z, Xu CG, Ren GS (2010) Study on deformation principle to forming shafts without concavity during near net shape cross wedge rolling process. In: Special Rolling Academic Conference Proceedings, Kunming, China, pp 71-74:25–27

    Google Scholar 

  16. Shu XD, Li CB, Zu WM. Rolling method of no scrap shafts by cross wedge rolling: China Patent, 200910154327.3.2010–06-09 (in Chinese)

  17. Zhu CB, Liu B. Special mold of rotary shafts without scrap by cross wedge rolling: China Patent, 201020103803.7.2010–09-29 (in Chinese)

  18. Hu B, Shu XD (2014) On end quality for roll-cutting billet without stub bar in cross wedge rolling. J Ningbo Univ 27(3):103–107

    MathSciNet  Google Scholar 

  19. Ma JD, Shu XD, Liu C (2015) Estimating criteria of roll-cutting blank end surface in cross wedge rolling without stub bar. Hot Work Technol 44(15):150–152 (in Chinese)

    Google Scholar 

  20. Yang G, Zhang KS, Duan WZ, Hu ZH (2014) Effect of process parameters on the end scrap of no-step-end workpieces by cross wedge rolling. J Univ Sci Technol Beijing 36(7):959–965

    Google Scholar 

  21. Peng WF, Zhang JH, Huang GX, Liu WP, Shu XD, Zhu J (2016) Stress distributions during the cross-wedge rolling of composite 42CrMo/Q235 laminated shafts. Int J Adv Manuf Technol 83:145–155

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Beijing Research Institute of Mechanical and Electrical Technology, No. 18 Xueqing Road, Haidian District, Beijing, 100083, China

    Jian Zeng, Chunguo Xu, Weiwei Ren & Pan Li

Authors
  1. Jian Zeng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Chunguo Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Weiwei Ren
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Pan Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jian Zeng.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zeng, J., Xu, C., Ren, W. et al. Study on the deformation mechanism for forming shafts without concavity during the near-net forming cross wedge rolling process. Int J Adv Manuf Technol 91, 127–136 (2017). https://doi.org/10.1007/s00170-016-9742-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-9742-6

Keywords

Search

Navigation