Additionally to the achievable tight geometrical tolerances, rotary swaging can influence intrinsic material properties by work hardening and residual stresses generation. Although residual stresses should be usually avoided, they can be used on purpose to improve the performance properties of a produced part. To find prospective process settings, 2D FEM simulation of the rotary swaging process was developed and revealed the development of residual stresses distributions in E355 steel tubes in the whole longitudinal section. Besides the closing time, also geometric features of the dies were varied. It was found that the closing time affects the residual stresses significantly at the surface, but not in the depth of the part. By shortening the calibration zone, the axial tensile residual stresses near the outer surface could be lowered, while compressive residual stresses near the inner surface remained almost unaffected. By applying a higher die angle, the tensile axial residual stresses were increased while reducing the compressive axial residual stresses. Experimental investigations of residual stresses were performed by X-ray diffraction which revealed a good agreement between simulation results and physical measurements. With these findings, the rotary swaging process can be optimized for shaping residual stresses profiles to improve the performance properties of the produced parts.

除了可达到的紧密几何公差外，旋转型锻还会通过加工硬化和残余应力的产生影响材料的固有性能。尽管通常应避免残余应力，但可以有目的地使用残余应力来改善所生产零件的性能。为了找到预期的工艺设置，开发了旋转型锻工艺的二维有限元模拟，并揭示了E355钢管整个纵向截面中残余应力分布的发展。除了关闭时间以外，模具的几何特征也有所变化。发现闭合时间会显着影响表面的残余应力，而不影响零件的深度。通过缩短校准区域，可以降低外表面附近的轴向拉伸残余应力，而内表面附近的压缩残余应力几乎不受影响。通过施加较大的模具角，可增加拉伸轴向残余应力，同时减小压缩轴向残余应力。通过X射线衍射对残余应力进行实验研究，结果表明模拟结果与物理测量值之间具有良好的一致性。有了这些发现，就可以优化旋转型锻工艺，以成形残余应力轮廓，从而改善所生产零件的性能。通过X射线衍射对残余应力进行实验研究，结果表明模拟结果与物理测量值之间具有良好的一致性。有了这些发现，就可以优化旋转型锻工艺，以成形残余应力轮廓，从而改善所生产零件的性能。通过X射线衍射对残余应力进行实验研究，结果表明模拟结果与物理测量值之间具有良好的一致性。有了这些发现，就可以优化旋转型锻工艺，以成形残余应力轮廓，从而改善所生产零件的性能。