Forming and uniformity of shaft parts without a stub bar by axial closed-open-type cross-wedge rolling

To realize cross-wedge rolling of shaft parts without a stub bar in a short process,an axial closed-open-type cross-wedge rolling technique was proposed.Based on the strain characteristics in the rolling,evaluation indices of deformation uniformity were provided,and the DEFORM-3D software was adopted to conduct numerical simulations of the rolling process.The metal flow and strain distribution in all stages of the rolling process were analyzed.It is shown that the strain value of the rolled piece close to the end is relatively high while the overall strain distribution is uniform in the rolling process.When the percentage reduction in area is smaller,the fluctuation range of the equivalent strain will be lower and the overall uniformity of the rolled piece will be better.A variable angle wedge was implemented to make metal flow inward and eliminate concavity.Finally,rolling experiment was performed,which indicate that the shape of the rolled piece obtained is consistent with the simulation results.Concavity value in the rolling is decreased by 92%as compared to conventional open rolling.The research results lay a theoretical basis for realizing closed-open-type cross-wedge rolling without a stub bar.

Cavity formation in cross-wedge rolling processes

The problem of end-face cavity formation in parts produced by cross-wedge rolling was studied in order to reduce material consumption.The cavity depth was measured by the displacemern method.Twenty-one different cases of rolling were analysed by finile element method to determine the effects of process parameters such as the wedge tool angle,the temperature of material,the tool velocity and the reduction ratio on the depth of end-face cavities.Relationships between these parameters are examined in order to establish depe ndencies enabling quick and simple selection of a con cavity allowance in order to remove the cavities.The equations for calculating the con cavity allowance were verified in an experimental process for manufacturing ball pins with the use of flat tools.Rolling tests were performed using a billet with its length selected in compliance with the established dependencies.The experimental results demonstrate that the proposed solution is a viable method for end-face cavity removal.

Cross-Wedge Rolling of Shafts With an Eccentric Step

A new concept for forming eccentric shafts on the basis of the cross-wedge rolling （CWR） process was presented. This concept was based on the application of special guides, which, by acting on a billet, lead to its controlled movement in the vertical direction. This movement made possible eccentric cutting of tools into the billet. FEM calculations and experimental rolling tests clearly confirmed the effectiveness of the proposed forming method.

Influence of process parameters on interracial tensile strength of crosswedge rolling of 42CrMo/Q235 laminated shafts

Through rolling experiments and interfacial tensile strength tests of cross-wedge rolled laminated shafts of 42CrMo/Q235 composites, the influence of process parameters, including forming angle, spreading angle, area reduction, rolling temperature and core material diameter on the interfacial shear strength was analyzed. The results show that the sequence of process parameters in order of greatest influence on interfacial tensile strength was rolling temperature, area reduction, core material diameter, forming angle and spreading angle. At the interface of the combined materials, tensile strength decreased as forming angle and spreading angle increased, whereas the tensile strength first increased and then decreased as area reduction, rolling temperature and core material diameter increased.