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Numerical and experimental study on the inner diameter uniformity of hollow shafts in cross-wedge rolling with mandrel

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Abstract

The precision forming of inner hole is one of technological bottlenecks in Cross-wedge Rolling (CWR) of hollow shaft with mandrel. The inner diameters show signs of characteristic fluctuation despite under the control of mandrel. The uniformity of inner diameter was investigated by finite element simulation and experiments in this study. The inner hole expands at the knifing stage and shrinks at the sizing stage. The dimensional fluctuation of inner diameter is mainly resulting from the improper metal flow. The radial and axial metal flows are insufficient at the knifing stage, which resulting in the hole expansion at knifing zone. The hole shrinkage is caused by the relatively adequate radial metal flow at sizing stage. The experiment results show that the hole expansion increases with the increasing stretching angle and mandrel diameter and decreases with the increasing forming angle and initial wall thickness. The hole expansion first increases and then decreases with the increasing reduction ratio. The hole shrinkage has positive correlations with forming angle, reduction ratio and initial wall thickness, and negatively correlates with stretching angle and relative mandrel diameter. A modified CWR roll with the curved-surface knife is proposed to get rid of the hole expansion. Based on experiments and simulations, the most suitable geometric parameters of the curved-surface knife are determined. Using mandrel diameter compensation can reduce the phenomenon of hole shrinkage. These methods were applied to the trial rolling of a half-shaft sleeve part, and the results show that the methods significantly restrain the inner diameter fluctuation.

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Acknowledgements

This work is supported by the National Key R&D Program of China (Grant no. 2018YFB1307900). This work is funded by the National Natural Science Foundation of China (Grant no. 51875036). This work is also supported by the Beijing Laboratory of Modern Transportation Metal Materials and Processing Technology and the Beijing Key Laboratory of Metal Forming Lightweight.

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Authors and Affiliations

  1. School of Mechanical Engineering, University of Science and Technology Beijing, No. 30 Xueyuan Road, Haidian District, Beijing, 100083, China

    Jing Zhou, Jinxia Shen, Baoyu Wang, Xu Huang & Wei Guo

  2. Engineering Research Center of Part Rolling, Ministry of Education, Beijing, 100083, China

    Jing Zhou & Baoyu Wang

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  1. Jing Zhou
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  2. Jinxia Shen
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  4. Xu Huang
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Zhou, J., Shen, J., Wang, B. et al. Numerical and experimental study on the inner diameter uniformity of hollow shafts in cross-wedge rolling with mandrel. Archiv.Civ.Mech.Eng 21, 104 (2021). https://doi.org/10.1007/s43452-021-00256-w

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