Research On Finite Element Simulation And Test Of Crankshaft Fillet Rolling

Crankshaft fillet rolling technique is widely used in today’s automobile enginemanufacturing industry. It is one of the indispensable crankshaft surface enhancementtechnology, but the rolling force which is the most important process parameter, is mainlydetermined by traditional process testing. This method is not conductive to the application ofpractical engineering because of the high cost and the long testing period. In order to improveefficiency and reduce cost, this article study on rolling force, combine computer finite elementsimulation with traditional technique testing to find a rolling force selection plan which iscloser to the application of practical engineering.Definite rolling force, rolling laps and crankshaft rotation speed on the influence ofcrankshaft fillet rolling through finite element simulation on4G1crankshaft fillet rollingprocess. Study focuses on the variation trend of the residual stress and rolling deformationunder different rolling force, and builds the correspondence relationship between residualstress and rolling distortion. Find the minimum rolling deformation to meet the4G1crankshaft fillet rolling design requirements, and combined with the practical experience,definite the target rolling deformation under the condition that ensure adequate margin ofsafety and well product costs. The residual stress after rolling can be predicted during therolling process testing which take rolling deformation as a bridge, provide the method onrolling force selection.To determine the actual corresponding relationship between the rolling force and rollingdeformation through the test on crankshaft fillet rolling, and to confirm the results of finiteelement simulation. Initial definite the rolling force according to target rolling deformation,and combine with rolling testing result. Carry out pilot production with selected rolling force,make sure the actual deformation meet the4G1crankshaft’s request or not on minimumrolling deformation.To make sure the fatigue limit of the crankshaft through bending fatigue testing on pilotproduction crankshaft, evaluate the rationality on rolling force selection, and complete theprocesses parameters selection on fillet rolling of4G1crankshaft.Completing the fillet rolling parameters selection with finite element simulation andprocess test, could be more effective to shorten the process testing and fatigue testing repeat count, cycle-time reduction and cost reduction, it is basically solved the problem that hard tomake selection on crankshaft fillet rolling force.