Abstract
Results of a study investigating a skew rolling process for elongated axisymmetric parts are presented. Despite the fact that the skew rolling technique for producing such parts was developed and implemented in the mid-twentieth century, there are no studies on this problem. The first part of this paper presents the results of FEM modelling of skew rolling stepped axles and shafts (solid and hollow). The FEM analysis was performed using the MSC Simufact Forming software. The numerical simulation involved the determination of metal flow patterns, the analysis of thermal parameters of the material during rolling, and the prediction of cracking by the Cockcroft-Latham ductile fracture criterion. Force parameters of rolling solid and hollow parts were also determined. The aim of the FEM analysis was to determine initial design assumptions and parameters for the development of the skew rolling mill. Later on in the paper, a design solution of a CNC skew rolling mill for rolling parts based on their envelope profile is proposed. FEM strength test results of a mill stand, obtained with MSC. NASTRAN, are presented. Finally, the performance test results of the constructed rolling mill are presented. The experiments involved rolling real stepped shafts that were modelled numerically. Obtained results show that the proposed skew rolling method has considerable potential. The designed and constructed rolling mill can be used to perform the rolling process according to the proposed method, with the tool and material kinematics being controlled based on the set parameters of a workpiece envelope.
Highlights
In recent years, the development of energy- and materialsaving manufacturing techniques has become one of the top challenges for the global industry
The concept of skew rolling elongated parts was first proposed in the 1960s [18, 19], and the first rolling tests took place at that time, too
The first stage of the study was a numerical analysis of a skew rolling process for stepped shafts
Summary
The development of energy- and materialsaving manufacturing techniques has become one of the top challenges for the global industry. Innovative solutions are sought in practically every branch of the economy to enable reduced energy and material consumption, shorter manufacturing time, and the reduction of harmful substances produced during manufacturing processes. This trend can be observed in the metallurgical and forging industries that by definition are considered to be among the most material- and energy-consuming as well as environment-unfriendly industries. A vast volume of forged parts are elongated parts such as stepped axles and shafts They are finished and semi-finished products of relatively simple shapes, their production requires the use of specialist machines and equipment due to large differences between their cross-sectional dimensions and length.
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