Study Of Forming Process For Big Size Cross Wedge Rolling Workpiece

For lately year, with the fast development of automotive industry especially the heavy truck, the demanded quantities of shaft parts with larger diameter are more and more imperative. As a perfect techniques to form shaft parts, cross wedge rolling (CWR) has been widely applied because of its lots of merits, such as remarkable saving material and higher produced efficiency, etc. The size of the equipment of CWR is increasingly bigger. But up to now, it is nearly not found in the world that study of techniques and equipment about oversize CWR, so its popularization becomes restricted. Hence, developing study of techniques and equipment about oversize CWR has importantly actual meaning and scientific value.This paper systematically analyzes that the deformation mechanism for larger diameter shaft parts to form with CWR method by using DEFORM-3D finite element method (FEM) software. It simulates the deformation condition of the different parts using FEM, contrasts the difference of the process with different diameter parts, and analyzes the damage of center location in different workpieces. It shows the distribution of stress and strain field in rolled workpieces and the pattern that techniques parameter's effect on stressing rolled workpieces, and establishes the important theoretical basis for choosing technical parameters of the dies.This paper studies the defects of the rolled workpieces, such as axial movement, the collapse of wedge, etc. It shows that the defects exist in almost every workpieces, and they are bigger in the big size workpieces than the smalls. Finally, it proposes a new forming process, and proves its feasibility by using FEM and experiment.