Research On Load Analysis And Forming Quality Of Spline Continuous Cold Shocked Forming Equipment

Spline Continuous cold shocked forming is a new cold volume shaping method to produce big modulus spline.When rolling wheels contact the surface of the workpiece,there will be a tiny plastic deformation.Then coupled with intermittent rotary motion and feeding motion of the workpiece,the spline can be produced.This method is a near net forming process that the spline can be directly formed by one time,and no material wasted during the production process.In addition,because of the plastic forming and cold hardening,the surface fiber of the workpiece cannot be broken and the tooth also has better strength.So this new forming process has been more and more concerned and studied because of the high efficiency,low cost,and good quality.This new method need it own equipment.In recent years,many researchers have focused on designing the transmission to complete the action.However,the load of the equipment and the factors which can influence the forming quality were barely considered.Here are the three points of my research.First,load.This paper studies on the load of the equipment by using ABAQUS and MATLAB,according to the actual working conditions,and analyzed the load characteristics.For the convenience of calculation and experiments,taking the impulse into consideration,an equivalent simplified load was selected from the common waveform load.Equivalence of the simplified load can be verified by calculating the life of the wearing parts.An experimental prototype is made which is used to measure the actual load.Second,deviation calculation with shock parts.Look at this picture,this is rolling wheel,this is roller,and they are connected by rotary pair.Based on the load above,when the rolling wheels shock the workpiece,the position of rolling wheels would deviate from the ideal position due to the elastic deformation of the shock parts and clearance in the rotary pair.A method is proposed for calculating this deviation.A elasticity model is built and analyzed.The actual situation of clearance is described by using vector method.There will be a collision due to the clearance,so a new collision model which considering the surface shape and the energy loss was put forward by analyzing two classic collision models.The deviation can be calculated by Adams Solver and verified by measuring produced workpiece.Last,feeding rate.The Feeding rate is one of the important parameters that influences the forming quality.The two lines are trochoid,shadow is deviation area.Considering the shape of the rolling wheels,the deviation distribute 3 dimensions.The deviation can be described from X axis and Y axis.The mathematical relation among the deviation,feeding rate and size of rolling wheels can be calculated.The results are proved by measuring the top and bottom of the tooth which is simulated in different feeding rate.