Process Parameters Decision to Optimization of Cold Rolling-Beating Forming Process through Experiment and Modelling

Long Li,Mingshun Yang,Tong Tong,Yan Li

doi:10.3390/met9040405

Abstract

The cold roll-beating forming (CRBF) process is a particular cold plastic bulk forming technology for metals that is adequate for shaping the external teeth of important parts. The process parameters of the CRBF process were studied in this work to improve the process performance. Of the CRBF process characteristics, the forming forces, tooth profile angle, surface roughness, and forming efficiency were selected as the target indices to describe the process performance. Single tooth experimental tests of ASTM 1045 steel were conducted with different roll-beating modes, spindle rotation speeds, and feed speeds. Using analysis of variance (ANOVA) and regression analysis, the influence of the process parameters in each index was investigated, and regression models of each index were established. Then, the linear weighted sum method and compound entropy weight method were used to determine the process parameters for multi-objective optimization. The results show that the impact capacity and optimum value range of the process parameters vary in different indices, and that, to achieve the comprehensive optimum effect of a small forming force, high product quality, and high forming efficiency, the optimal process parameter combination is the up-beating mode, a spindle rotation speed of 801 r/min, and a feed speed of 960 mm/min.

Highlights

As important mechanical products, gears, spline shafts, and other transmission parts are widely used in various mechanical products [1,2], the rapid development of major industries, such as automobile, aircraft, special engineering machinery, and wind and nuclear power equipment, has led to a huge demand for transmission parts with higher performance [3,4]
During the cold roll-beating forming (CRBF) process, the metal is subjected to intermittent impacts at a certain frequency, and the deformation produced by each impact is small
Fz is the main of forming force in the CRBF process, and the forming in The the forming force in the z-direction z is the mainload forming force in the CRBF

Summary

Introduction

Gears, spline shafts, and other transmission parts are widely used in various mechanical products [1,2], the rapid development of major industries, such as automobile, aircraft, special engineering machinery, and wind and nuclear power equipment, has led to a huge demand for transmission parts with higher performance [3,4]. In the production of mechanical parts, objectives such as creating a lightweight design, establishing short process chains, and improving material and energy efficiency are difficult to meet using the current cutting methods to shape the external teeth of transmission parts [3,5,6]. Among the varieties of plastic forming technologies, cold roll-beating forming (CRBF) is an incremental metal bulk forming technology for forming the external teeth of high-load transmission parts, and it has the advantages of environmental protection, flexibility, and lower cost. It has a wide range of application prospects in the automobile industry, the aerospace sector, and equipment manufacturing [9,10,11]

Methods

Results

Discussion

Conclusion