Surface work-hardening optimization of cold roll-beating splines based on an improved double-response surface-satisfaction function method

Fengkui Cui,Libo Liu,Yongxiang Su,Xiaoqiang Wang,Xiaolin Ruan,Xiang Yu

doi:10.1177/1687814018782630

Abstract

The work hardening of a spline during cold roll-beating is used as an indicator to evaluate the mechanical properties of the surface. To further optimize the work-hardening degree of a cold roll-beating spline surface, weight theory and satisfaction functions are used to improve the double-response surface-satisfaction function model. The model describes the involute spline based on the cold roll-beating speed and feed rate. The generalized reduced-order gradient method is applied to optimize the optimal combination of processing parameters. The experiments validate the optimization results of the improved double-response surface-satisfaction function method and the conventional response surface method based on the cold roll-beating spline test and a comparative analysis of the spline surface metallographic structure. The results show that the satisfaction degree of the improved response model is 0.87384, indicating that the model is robust and reliable. The optimized processing parameters are a cold roll speed of 1448.21 r/mm, a feed rate of 41.71 mm/min, and a degree of work hardening of 144.79%. The spline surface work-hardening degree based on the revised model is higher than that of the conventional model. Thus, the improved double-response surface-satisfaction function model provides better accuracy.

Highlights

High-speed cold roll-beating forming technology is an advanced plastic-forming technique in which the highspeed rotation of a roller on the workpiece beats and rolls intermittently while forcing metal materials to flow, relying on the natural plasticity of cold metal materials
The cold roll-beating forming process is a gradual forming process of nonuniform thermodynamic coupling, which inevitably produces a certain degree of work hardening due to the role of
The performance and processing requirements of cold roll-beating workpieces depend on the application field

Summary

Introduction

High-speed cold roll-beating forming technology is an advanced plastic-forming technique in which the highspeed rotation of a roller on the workpiece beats and rolls intermittently while forcing metal materials to flow, relying on the natural plasticity of cold metal materials. C Fengkui et al based the establishment of the spline coldrolling mathematical model on the involute splineforming process and analyzed the relationship between the components of spline cold roll-beating and studied the effects of spline surface grains, dislocations, and work-hardening layers on different parts of the spline teeth according to the principle of cold roll-beating forming. The optimization results of the improved model are validated using the conventional model optimization results by applying a cold roll-beating spline-forming test and by analyzing the change in the metallographic structure This validation establishes a more accurate mathematical model of spline surface work hardening intended to achieve control of the work-hardening degree and optimal selection of optimum process parameters in splines during the cold roll-beating process. The microstructure of the spline teeth was observed under a JSM-5610LV scanning electron microscope (SEM)

Experimental procedures

Conclusion