Numerical Simulation Of Precision Forming Spline Cold Hit

Spline cold rolling as a new type of non-machining technology makes themetal of workpiece surface produce local plastic deformation to achieve splineintegral forming using specific tooth rolling wheel high-speed percussion andextrusion. Compared with traditional method of spline processing, the processhas the advantages of high productivity, energy conservation and nodal wood,forming parts with high precision and mechanical performance, etc., and iscurrently the advanced technology of manufacturing high-precision,high-strength, high-performance spline shaft parts, which has been widely usedin automotive, aerospace, shipbuilding, defense industry and many otherindustries, so it has a broad development prospects.By studying the spline cold rolling on the forming principle andcharacteristics, the effect of strain rate effect, inertial effect, stress wavepropagation effect and adiabatic effect on the spline cold rolling process wereanalyzed. Dynamic yield criterion and dynamic constitutive relation applying tospline cold rolling were studied and identified. Spline tooth formation conditionsand the rotational speed of the workpiece adopting interrupted division werecalculated. The actual production simulation provided a theoretical basis.According to the characteristics and influencing factors of the spline coldrolling process, by solving the key problems, such as simplified geometricmodel, material modeling, rolling wheel and workpiece motion control, contactboundary condition definition, field output setting and meshing, a complete3DFE modeling of involute spline intermittent indexing cold rolling wasestablished by ABAQUS software using the dynamic explicit finite elementmethod. By numerical simulation, the distribution and evolution law of stress,strain and evolution law of force and energy of spline cold rolling were revealed.And from the angle of the energy, the reliability of the model was verified. Thestudy provided a base for further research on the deformation mechanism ofspline cold rolling. On the basis of a reliable FE modeling, the influence rules of cold rolling parameters including tool rotation speed, workpiece axial feed speedand friction coefficient on the force, strain distribution and the axial flow ofmetal were systematically studied. The study provided guidelines for the designand optimization of the cold rolling parameters in the actual spline cold rollingproduction.