Abstract
This paper presents the numerical and experimental results of investigating the effect of geometrical parameters of tubular specimens on the rotary compression process for hollow axisymmetric shafts with central necking, and their accuracy. The numerical investigation was performed using the finite element method (FEM) with the Simufact Forming simulation software suite. The simulations investigated the effect of tubular specimen wall thickness on the kinematics of metal flow and the geometry of produced shafts. The results were validated in experimental tests using a forging machine designed specifically for this purpose.
Highlights
Hollow parts, such as stepped axes, shafts, tubes, rings and many other axisymmetric parts, have a variety of applications, from automotive and aircraft structures to household appliances [1]
The proposed new rotary compression method for hollow parts can be successfully employed in both small series and mass production, as it is based on the use of simple tools and devices
The use of hollow tubular specimens in rotary compression leads to lower consumption of both material and energy, which, in turn, results in lower production costs
Summary
Hollow parts, such as stepped axes, shafts, tubes, rings and many other axisymmetric parts, have a variety of applications, from automotive and aircraft structures to household appliances [1]. Metal-forming methods for producing hollow parts ensure reduced material consumption as well as enhanced strength properties of parts (fibre continuity is maintained). Rotary compression is a metal-forming operation based on the technique of cross rolling with three rolls, in which the tools rotate, but they simultaneously travel towards the axis of the work piece In this process, sections of commercial tubes or sleeves are rotated and deformed to reduce the diameter of steps. Strojniški vestnik - Journal of Mechanical Engineering 61(2015) 149156 offers numerous benefits, including lower forming forces, reduced material consumption, increased strength properties of produced parts, enhanced process efficiency, lower implementation and production costs, as well as simple design of the process and the possibility of its automation. The model of C45 steel used in the computations was taken from the library database of the software used and is defined by:
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