Numerical Simulation And Process Research On Incremental Cold Rolling For Spline Tube With Two Rollers

As the key parts for transmission of power and torque, the hollow spline tube is often applied in those spline connections, which needs high centering precision, high torque transfer capability or high transmission slip ratio. So, it is widely used in a variety of vehicles and equipment manufacturing industry. The precision cold roll forming is one kind of less or no cutting process. Due to its no destroying on the part surface fiber, it has a continuous metal tooth surface fiber, and many other advantages such as high wear resistance, high forming efficiency, material saving and so on. The spline tube differs greatly from the spline shaft parts in the cold roll forming process, which has a complex process with large blank deforming quantity. The production process is therefore different from the traditional production process of the spline shaft, and there is almost no relative research for the domestic enterprises. According to the analysis of development trends of rolling technology, we can see that it is necessary to accurately describe the Stress and Strain Field, the metal flow law and load prediction through Finite Element Analysis (FEA) on cold rolling for spline tube, as well as metal forming mechanism.By taking incremental cold rolling as research object, and taking the hollow spline tube as the carrier of the research object, the paper analyzed the feasibility of forming of spline tube by adopting cold rolling process. According to practical situation, it carried out die designing, interference detection, parameter conditions preliminarily determine based on theoretical analysis. By the results of simulation, the paper modified the parameters repeatedly to make every indexes tend to be more reasonable in order to realize forming the high quality deformed parts by low-cost and simpler equipment and technical conditions.Through FEA on cold rolling for spline tube and the analysis of the Stress and Strain Field, the metal flow law and load prediction, the result shows that the optimized parameters for the process are as follows: blank sizeφ60×3.5mm, press quantity 50%/30%/20%,friction coefficient 0.12 and speed of roller 36/rpm. Under this condition, the metal plastic flow is uniform, the values of equivalent stress and equivalent strain are smaller, and rolling force is more reasonable. Meanwhile, some issues in simulation were analyzed, and the respective solutions were proposed.At the final, the physical experiment was carried on the retrofit of screw machine. The Experiment verification proves the correctness and reliability of above theoretical analysis and simulation.