The Mold Design Of Cross Wedge Rolling With Eccentric Shaft And Numerical Simulation

Cross-wedge rolling (CWR) process belongs to modern forming methods, which is anew highly efficient metal plastic forming technology method and has the advantages ofhigh efficiency, low cost. After years of development, the Cross-wedge rolling process iswidely applied for the production of shafts. Using the Cross-wedge rolling processforming eccentric shaft can greatly improve the production efficiency, and reduce the costof subsequent processing. So the concept for forming eccentric shafts on the basis of thecross-wedge rolling process was presented, which has important theoretical significanceand practical value. The main research work in this paper is outlined as follows:At first, this article puts forward the application of forming the eccentric shaft withtwo-dimensional cross-wedge rolling technology after the analysis of the rolling principleof cross-wedge rolling, and then study the eccentric shaft rolling method. Take a kind ofeccentric shaft as a case to study the mold design. And choose reasonable technologicalparameters by calculation, established the special curve equation of mold wedge.The second, based on the module GUI in the software MATLAB design graphics userinterface, achieving the functions of preliminary calculation of wedge rolling curve shape.Then, the effect that the parameter of the curve equation causes on the shape of rolledpiece has been analyzed. This graphic image makes it possible to repeat calculation andprovide valid data for simulation and experiment.On grounds of finite elements method, two-dimensional mechanical model of crosswedge rolling process has been established, that simulated the whole forming process ofthe eccentric shaft. Examples of numerical simulation for effective strain distributions,effective stress and rolling load have been included. The results of numerical calculationsverify the rationality of the mould design and the correctness of the established curve. Atthe same time analyzed the strain in different stage of transverse and longitudinaldistribution on cross section and the stress and strain distribution on the circumference ofa circle. After that the forming rule of the eccentric shaft and the reason of the roundnesserror of eccentric part and the load conditions of the mold has been analyzed, this providetheoretical basis for mold design and manufacturing of eccentric shaft with cross wedge rolling.