Cold Rolling Precision Forming of Shaft Parts (eBook)

Preface 5
Contents 8
Introduction 14
Abstract 15
1 General Introduction 16
Abstract 16
1.1 Introduction of the Cold Rolling Precision Forming Technology 16
1.2 Present Situation of Shaft Part Manufacturing Technology 18
1.2.1 Cutting of the Spline Shafts 19
1.2.1.1 Cutting with Formed Cutter 19
1.2.1.2 Generating Cutting Method 20
1.2.2 Plastic Forming of Spline Shafts 21
1.2.2.1 Cold Extrusion Forming of the Spline Shafts 22
1.2.2.2 Cold Rolling Forming of Spline Shafts 23
1.2.2.3 Striking Rolling of the Spline Shafts 24
1.2.2.4 Cold Rolling Forming of Spline Shafts with Rack Dies 25
1.2.2.5 Cold Rolling Forming of Spline Shafts 27
1.2.3 Manufacturing Methods of Thread Components 28
1.3 Research Progress on the Cold Rolling Precision Forming Technology of Shaft Parts 31
1.3.1 The State of the Art on the Manufacturing of Spline Shafts 31
1.3.2 Theoretical Researches on the Cold Rolling Forming of Spline Shafts 34
1.3.3 Surface Modification of the Cold Rolling Forming Spline Shafts 35
1.3.4 Development Status on Cold Rolling Forming of Threads 36
1.4 Development Trends on Cold Rolling Precision Forming Technology of Shaft Parts 38
References 40
2 Principle and Mechanical Analysis on the Cold Rolling Precision Forming of Spline 44
Abstract 44
2.1 Principle and Process on the Cold Rolling Precision Forming of Spline Shafts 44
2.2 Mechanical Analysis 46
2.3 Analysis on the Cold Rolling Forming Process of the Spline Tooth 47
2.3.1 Indexing and Biting Conditions [6] 47
2.3.2 Rotating Conditions 47
2.3.3 Geometrical Indexing Conditions 50
2.4 Double-Flank Non-backlash Meshing 52
2.4.1 Contact Area in the Forming Process 52
2.4.2 Position of the Contact Points 55
2.4.2.1 Position of the Contact Point on the Bilateral Tooth Surfaces of the Spline 55
2.4.2.2 The Position Parameters of the Contact Point on the Rollers 58
2.5 Sliding of the Contact Point 59
2.5.1 Sliding Motion of the Contact Point on the Active Tooth Flank 59
2.5.2 Sliding Motion of the Contact Point on the Driven Tooth Flank 61
2.5.3 Metal Flow on the Tooth Surface of the Workpiece 62
2.6 Mechanical Analysis on the Cold Rolling Precision Forming of Spline 63
2.6.1 Basic Assumption of the Stress Analysis 63
2.6.2 Fundamental Plastic Forming Theory of Stress Analysis 65
2.6.2.1 Fundamental Equation of the Plane Strain 66
2.6.2.2 Yield Criteria 67
2.6.2.3 The Strengthening Model 68
2.6.2.4 The Slip-Line Stress Field Theory 68
2.6.3 Slip-Line Field and Stress Analysis in the Initial Rolling Stage 70
2.6.4 Slip-Line Field and Stress Analysis in the Stable Rolling Stage 72
2.7 Average Pressure on the Contact Surface During the Forming Process 75
References 78
3 Process Parameters in the Cold Rolling Forming of Spline 80
Abstract 80
3.1 Contact Area in the Cold Rolling Forming of Spline Shafts 80
3.1.1 Calculation Model 81
3.1.2 Tooth Profile Equation of the Roller and the Workpiece in the Forming Process 82
3.1.2.1 Tooth Profile of the Roller 82
3.1.2.2 Tooth Profile of the Workpiece 85
3.1.3 Contact Boundary Conditions 88
3.1.4 Calculation of the Contact Area 89
3.1.5 Main Algorithm of the Subroutine 91
3.1.5.1 Solution Program for the Judgment of the Intersection Point Between the Involute and the Circle 91
3.1.5.2 Calculation Program of the Contact Arc Length on the Roller Tooth Addendum Transition Circle 91
3.1.5.3 Calculation Program of the Arc Length on the Involute 92
3.1.5.4 Important Parameters Necessary for Calculation 93
3.1.5.5 Analysis of the Factors Influencing the Unit Length Contact Area 99
3.2 Rolling Force and Rolling Moment 100
3.2.1 Theoretical Calculation of the Rolling Force and Rolling Moment 100
3.2.2 Analysis of the Rolling Force and Rolling Moment in the Forming Process 102
3.3 Calculation of the Cold Rolling Workpiece Billet Diameter 106
3.3.1 Theoretical Calculation Formulas 106
3.3.2 Cross-Sectional Area of a Single Tooth Above the Dedendum Circle 106
3.3.3 Radius of the Dedendum Transition Arc 109
4 Numerical Simulation on the Cold Rolling Forming of Spline 112
Abstract 112
4.1 Establishment of the Finite Element Model and Boundary Conditions 112
4.1.1 Finite Element Model 112
4.1.2 Simulation Parameters and Constrain Conditions 113
4.2 Numerical Simulation of the Cold Rolling Forming Process 113
4.2.1 Plastic Deformation Zone 113
4.2.2 Bulge at the End of the Shafts 114
4.2.3 Stress and Strain Fields 116
4.3 Comparison Between the Theoretical Analysis and Numerical Simulation Results 119
4.3.1 Unit Pressure on the Contact Area 119
4.3.2 Rolling Force in the Rolling Forming Process 123
References 124
5 Metal Flow Rules and Forming Quality of Cold Rolling Forming Spline Shaft 125
Abstract 125
5.1 Metal Flow Rules of the Tooth in Cold Rolling Precision Forming of Spline Shafts 125
5.1.1 Workpiece Billet and the Forming Parameters 125
5.1.2 Metal Flow Analysis of the Tooth Profile 126
5.2 Precision of the Spline Cold Rolling Forming Process 128
5.3 Surface Quality of the Cold Rolling Forming Spline Shaft Parts 130
5.3.1 Surface Roughness of the Formed Components 130
5.3.2 Tooth Surface Hardness of the Cold Rolling Forming Components 131
5.3.3 Microstructure of the Cold Rolling Forming Spline Tooth 133
5.3.4 Tooth Surface Strengthening Mechanism of the Cold Rolling Precision Forming Spline Shaft 135
5.4 Forming Error and Defects of the Cold Rolling Forming Spline 136
5.4.1 Formation and Control of the Accumulated Pitch Error 136
5.4.1.1 Variation of the Circular Pitch in the Cold Rolling Forming of Spline Shaft 136
5.4.1.2 Influence of Process Parameters on the Accumulated Pitch Error 138
5.4.1.3 Control of the Accumulated Pitch Error by Synchronization of the Roller and Workpiece Rotation Speed 140
5.4.2 Defect Analysis of the Cold Rolling Forming Spline Shaft 141
5.4.2.1 Disorder of the Tooth and Mistake of the Teeth Number 141
5.4.2.2 Tooth Profile Defects 142
5.4.2.3 Rough and Chipped Tooth Surface 143
5.5 Quality Control Methods of Cold Rolling Forming Spline Shafts 144
5.5.1 Design of the Cold Rolling Billet 144
5.5.2 Setting of the Roller and Adjustment of the Tooth Positions 146
5.5.3 Reasonable Selection of the Process Parameters 147
References 149
6 Mechanism and Process Analysis on the Cold Rolling Forming of Threads 151
Abstract 151
6.1 Principle of the Thread Cold Rolling Forming Process 151
6.1.1 Two-Wheel Rolling of Threads 152
6.1.2 Three-Wheel Rolling of Threads 153
6.2 Diameter Conditions of Three-Wheel Rolling Threads 154
6.3 Cold Rolling Forming Process of Threads 155
6.4 Relative Movement Between the Workpiece and the Rolling Wheel 158
6.4.1 Axial Motion Relationship 158
6.4.2 Rotational Motion Relationship Between the Workpiece and the Rolling Wheel 160
6.4.3 Relative Sliding Between the Rolling Wheel and the Workpiece 162
Reference 164
7 Process Parameters in the Cold Rolling Forming of Threads 165
Abstract 165
7.1 Thread Billets Before Cold Rolling Forming 165
7.1.1 Commonly Used Calculation Formulas of the Workpiece Billet Diameter 165
7.1.2 Solution of the Billet Diameter of the Cold Rolling Forming Thread 167
7.1.2.1 Flat Addendum and Dedendum of the Thread Tooth 167
7.1.2.2 Round Addendum and Flat Dedendum of the Rolling Wheel Tooth 169
7.1.3 Chamfer of the Billet 170
7.1.4 Material of the Rolling Billet 171
7.2 Parameters in the Cold Rolling Forming Process of Threads 174
7.2.1 Rolling Force 174
7.2.1.1 Mechanical Analysis of the Rolling Process 174
7.2.1.2 Factors Influencing the Cold Rolling Force of the Thread 176
7.2.1.3 Calculation of the Rolling Force 181
7.2.2 Selection of the Rolling Speed 184
7.2.3 Selection of the Feed Rate in Thread Rolling 185
7.3 Cold Rolling Forming of Hollow Thin-Walled Thread Components 187
7.3.1 Cold Rolling Forming of Hollow Threads 187
7.3.1.1 Elastic Deformation in the Cold Rolling Forming of Hollow Threads 187
7.3.1.2 Plastic Deformation in the Cold Rolling of Hollow Threads 187
7.3.1.3 Repairing of the Deformation in the Finishing Stage of the Hollow Thread Rolling 188
7.3.2 Wall Thickness of the Cold Rolling Hollow Thread Components 188
7.3.2.1 Wall Thickness Condition in Two-Wheel Rolling of Thin-Walled Thread Components 189
7.3.2.2 Wall Thickness Condition in Three-Wheel Rolling of Thin-Walled Components 195
References 199
8 Numerical Simulation of the Thread Cold Rolling Forming Process 200
Abstract 200
8.1 Basic Procedure and Assumptions 200
8.1.1 Numerical Simulation Procedure of the Thread Cold Rolling Process 200
8.1.2 Simplification of the Model 201
8.2 Simulation of the Cold Rolling Forming Process of a M10 × 1.5 Solid Thread 201
8.2.1 Load and Moment of the Die (Rolling Wheel) 203
8.2.2 Stress State Analysis of the Workpiece 207
8.3 Numerical Simulation on the Cold Rolling Forming of Hollow Threads 209
8.3.1 Analysis of the Rolling Force 210
8.3.1.1 Radial Load of the Rolling Wheel 210
8.3.1.2 Tangential Load of the Rolling Wheel 211
8.3.1.3 Axial Load of the Rolling Wheel 211
8.3.1.4 Torque 212
8.3.2 Velocity Field 212
8.3.3 Stress State of the Workpiece 214
8.3.3.1 Variation of the Stress Field 214
8.3.3.2 Stress State of the Characteristic Points in the Threads 214
8.3.4 Analysis of the Strain State 217
8.4 Failure Analysis of the Thread Components 217
8.4.1 Variation of the Effective Stress in the Workpiece 217
8.4.2 Repairing Action of the Three Rolling Wheels on the Instability of the Hollow Thread 219
References 221
9 Metal Flow and Parameter Optimization of Thread Cold Rolling Forming Process 222
Abstract 222
9.1 Cold Rolling Forming of Threads with Three-Wheel Rolling Machine 222
9.1.1 Material of the Billet and the Forming Machine 222
9.1.2 Factors Influencing the Cold Rolling Forming Process of Threads 223
9.1.3 Influence of the Hollow Thread Wall Thickness on the Forming of Threads 225
9.2 Metal Flow Rules in the Cold Rolling Forming Process of Threads 226
9.3 Hardness Distribution of the Cold Rolling Forming and Cutting Threads 230
9.4 Optimization of the Rolling Parameters 233
9.4.1 Determination of the Orthogonal Factors, Levels, and Index of the Thread Cold Rolling Forming Parameters 233
9.4.2 Hardening Degree Under Different Forming Conditions 235
9.5 Determination of the Optimized Rolling Parameters 235
References 238
10 Cold Rolling Precision Forming Equipments 239
Abstract 239
10.1 Summary 239
10.2 Design of the Cold Rolling Forming Machine and the Rolling Wheel 242
10.2.1 Structure and Parameters of the Equipment 242
10.2.2 Design of the Synchronous Spindle Damping Absorption 243
10.2.3 Modeling and Simulation of the Hydraulic System 245
10.2.3.1 Structural Principle of the Hydraulic System 245
10.2.3.2 Setting up of Simulation Model on the Hydraulic System 246
10.2.3.3 Dynamic Simulation of the Hydraulic System 248
10.2.4 Design of the Rolling Wheel 253
10.3 Measuring System of the Mechanical Parameters 255
10.3.1 Measurement Method of the Spindle Torque 255
10.3.2 Measuring of the Radial Feeding Force of the Slider 257
10.3.3 The Data Acquisition System 258
10.4 Determination of the Process Parameters 259
10.4.1 Rotation Speed of the Rolling Wheel 259
10.4.2 Feed Rate of the Rolling Wheel 260
10.4.3 Control of the Spindle Positions 261
10.5 Mechanical Parameters in the Cold Rolling Precision Forming Process 262
10.5.1 Dynamic Load of the Forming Process 262
10.5.2 Influence of the Process Parameters on the Maximum Forming Force 264
10.5.2.1 Influence of the Roller Rotation Speed on the Maximum Rolling Force 265
10.5.2.2 Influence of the Roller Feed Rate on the Maximum Rolling Force 266
10.5.3 Comparison Between the Theoretical Calculation and Experimental Results 267
10.6 Brief Introduction of the Cold Rolling Precision Forming Equipments 268
10.6.1 Cold Rolling Forming Equipments of Kinefac Corporation(Kinefac) in the USA [1] 268
10.6.1.1 Kine-Roller® Cylindrical Die Rolling Machines 268
10.6.1.2 PowerBox Two Cylindrical Die Machines 269
10.6.1.3 Double-Arm Two Cylindrical Die Machines 272
10.6.1.4 Three Cylindrical Die Rolling Machines 273
10.6.1.5 Rolling Dies and Typical Components 275
10.6.2 Cold Rolling Equipments of Profiroll Corporation in Germany [2] 275
10.6.2.1 Rollex Serial Spline Cold Rolling Machines 276
10.6.2.2 Thread and Profile Rolling Machines 279
10.6.2.3 CNC Thread Rolling Machines for Highest Profile Quality 282
10.6.3 Cold Rolling Forming Equipments of Qingdao Shengjian Machinery Factory [8] 284
10.6.3.1 Spline Cold Rolling Forming Machine 284
10.6.3.2 Numerical Control Rolling Machines 285
References 288