Research On Shaft Parts With Tapered Steps Forming By Cross Wedge Rolling

Cross wedge rolling technology is a new type of metal plastic formingtechnology. It has a high utilization of materials, long mold life, high productionefficiency.Now cross wedge rolling technology is used in the production of shaftparts in the agriculture, automotive, aerospace and other fields. With the developmentof industry, the requirement of the shaft parts on quality and accuracy have been morestrict in various fields. Therefore, the requirements of cross wedge rolling technologyare increasingly high. Because the cross wedge rolling forming process is complicated.There are still many problems to be solved in the process adjust and die design, Whenit is used to make the shaft parts with the cone angle greater than30°,if you use thetraditional cross wedge rolling, it is hard to guarantee the quality of the shafts, whichwill lead to neck shrank and other defects. Now people usually use cross wedgerolling mold with shaping curve to produe rolling, but the shaping curve is irregularspace curve. it has complex curve equation, which bring very great difficulties todesign and make the mold.In this paper, a new type of cross wedge rolling molding technology—doublemolding surfaces of cross wedge rolling technology is given to slove this problem..The difference between double molding surfaces method and the traditional crosswedge rolling technology is double molding surfaces method has tow moldingsurfaces. The mold consists of four parts by: wedge segment, the first broadeningsegment, the second broadening segment, the plasticing segment. The two moidingsurfaces have different forming angle. The first forming the angle of the formingsurface is less than30°or30°(Generally choice30°), the second forming angle ofthe molding surface is more than30°. Shaft parts with the tapered steps can be completed maked by this method of forming, and the mold is easier to be maked. Inthis article mainly gives the mold design schemes of this new cross wedge rollingforming technology, and uses finite element simulation technology to simulationdouble molding surfaces method. Analysising the internal stress, strain law of themolding process and the impact of different process parameters on the internal stressand strain.By the finite element simulation technology, discussing the doublemolding surfaces method for processing a large tilt angle cone shaft feasibility.The double forming surfaces of cross wedge rolling technology also belong tothe cross wedge rolling technology. Cross wedge rolling forming process has thecomplex deformation mechanism. The metal occurred nonlinear deformation. It isdifficult to accurately grasp the internal deformation law by using the traditionalphysical simulation experiment. So in this article using the finite element simulationtechnology to do the finite element simulation of double forming surfaces method.Finite element technology is a new technology which developed gradually with thedevelopment of computer technology. Having a wide range of applications inindustrial, medical, agriculture and other fields. The finite element simulationtechnology makes the metal plastic forming process happen in the computer. In thisway we can save the costs of experiment, short the time of experiment, and make theprocess has reproduciblity. It has important significance for people to grasp the lawand mechanism of deformation of the billet internal metal.In this paper, using the DEFORM-3D software to do simulation analysis. Firstuseing CATIA to establish the molds then importing them to the DEFORM-3Dsoftware, Using the stress, strain analysis capabilities and point tracking of thesoftware to simulation analysis the entire forming process of the double formingsurfaces of cross wedge rolling. To get the internal stress, strain variation and theaffects of the different process parameters on the entirely forming process. Finally,using the cross wedge rolling machine to produce the rolling by the double formingsurfaces technology of cross wedge rolling. Then combining the results of finiteelement simulation to verify the feasibility of double in the actual production.