Abstract
Rotary swaging is an incremental cold forming process for rods and tubes. Infeed rotary swaging with structure in the reduction zone of the tools is investigated using a two dimensional finite element simulation. A few geometrical parameters are varied, for cosine and skew stairway shapes. The effective tool angle is kept constant. The influence is evaluated by the radial and axial process forces. Furthermore, the material flow is visualized by the neutral plane. The simulation results are quantitatively compared to each other to analyse the reaction force F A , which acts against the feeding force. Also, the results serve to find suitable geometries to be transferred to rotary swaging tools for practical application. It is shown that the shapes have a significant effect on the forces and the location of the neutral plane. Finally a first swaging tool is modified with an exemplary geometry for experimental investigations.
Highlights
Rotary swaging has an important field of application in the automotive industry for the production of axes, steering spindles and gear shafts
The process forces and the material flow are studied during infeed rotary swaging with different shapes with varied geometric parameter values in the reduction zone of the tools
First insights are gained into the effect of geometry in the reduction zone of the tools by the presented simulation model
Summary
Rotary swaging has an important field of application in the automotive industry for the production of axes, steering spindles and gear shafts It features advantages like improved material properties as increased tensile strength, undisturbed fibre flow and for hollow shafts the variable wall thickness for an optimal use of material resources. Different designs of the reduction zone of the tools are investigated like convex, concave and hybrid contours [7].
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