Effects of process parameters on forming force and accuracy in cold roll-beating forming external tooth groove

Abstract

Cold roll-beating forming is an incremental cumulative plastic forming technology that uses rolling wheels to impact and roll a metal target at room temperature. The process parameters of cold roll-beating forming influence the forming process and its accuracy. In this paper, these influences are studied for the case of cold roll-beating forming an external tooth groove. First, the process and characteristics of cold roll-beating forming are analyzed to determine the key process parameters for forming external tooth grooves. Next, forming experiments and finite element simulations are carried out for roll-beating AISI 1045 (DIN C45). The forces, material deformation, and formed surface characteristics are analyzed for the process of cold roll-beating forming of an external tooth groove. Finally, the effects of the roll-beating method, spindle speed, and roll-beating density on the forces, forming defect, angle of the groove profile, and surface roughness are discussed. This study will serve as a reference for reducing forming force, restraining adverse deformation, and controlling forming quality by optimizing process parameters.