Research On Spline Precision Controlling Shape With Roller-beating

Spline cold rolling is a new multi-pass cold forming technology, the basic principle of that is using a specific roller which has a high-speed rotation to hit the workpiece, while the roller rotate around its axis. Since the high-speed kinetic energy loads on the deformation zone at a short time, and then transforms into plastic deformation energy, therefore plastic deformation occurs only in contact area, the hardened layer distributes in a certain depth. And because of the roller rotating with its axis compacts the surface of deformation zone, the quality of surface becomes better. Multi-pass cold forming can realize the efficicently and continuous forming of three-dimensional curved surface of spline, gear and cylindrical workpiece. It has a high potential for engineering applications.The paper makes the theoretical analysis of metal plastic deformation based on the principle of multi-pass cold forming. The prediction error has been evaluated to the mathematical model of the existing constitutive relation with high strain rate. The applicable constitutive model of spline cold forming has been determined through comparative study. The mathmetical model of relationship between roller and workpiece has been established to obtain the analytical solution of contact area. The variable technological parameters have been introduced to obtain the variable regularity of contact area at each pass var numerical simulation method of Matlab. The stress and velocity field distributing on deformation zone can be established var applying slip line field theory, which can provide a theoretical support for following research.The stress and strain distribution regulation of single tooth forming process can be obtained by the simulation of spline cold forming process var the powerful functional module of ABAQUS to solve the problem of nonlinear dynamics. The metal flow rule has been revealed through 3D technology by tracking the history change of node coordinate information. The regularity of each pass affecting non-contact stress and strain distribution can be researched by post-processing of the calculation results. Finally evaluate the shape of single tooth.This issue reveals the flow rule of metal at different pass, describes the affect regularity of each pass to spline, and provides an important guidance for precise shape controlling and process optimization.