Theory And Process Research Of Flexile Rolling For Shaft Forgings

Step Shaft Forgings are widely used in industrial practice. With the development trend of versatility and small mass production, the flexile rolling for shaft forgings is very importunate. This paper presents the process of flexile rolling for shaft forging and studies its theory and process, supported with National Natural Science Foundation of China.With theoretical and kinematical analysis, main process parameters, movement relationships between rollers and workpiece have been proposed. The rotary condition of workpiece has been presented and the relationship between the rotary condition of workpiece and process parameters are obtained. Mathematic expression of the contact surface between roller and workpiece are also obtained. Those results are helpful for understanding for this process.The deformation of process has been simulated with DEFORM-3D FEM software. The material flowing law, strain and stress distribution, temperature field, deformation load have been studied. The central material damage distribution is obtained based on the analysis of central stress field, and the result is consistent with the experiment. The simulation results are foundation of the rolling machine design.The experimental rolling machine had been designed and manufactured. The rolling samples are obtained by rolling experiment with different material. The load are tested with electrical test method and compared with theoretical calculation. Those results are helpful for the design and development of rolling machine.