Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve
Abstract
:1. Introduction
2. Forming Process Design for the Axle Sleeve
3. Numerical Simulation
3.1. The Finite Element Model of CWR
3.2. The Finite Element Model of Hot Extrusion
4. Numerical Simulation Results
4.1. Numerical Simulation Analysis of CWR
4.1.1. The Forming Results
4.1.2. Analysis of Stress Distribution
4.1.3. Analysis of Strain Distribution
4.1.4. Analysis of Axial Displacement
4.1.5. Analysis of Rolling Force
4.2. Numerical Simulation Analysis of Hot Extrusion
4.2.1. Analysis of the Workpiece Temperature
4.2.2. Analysis of Metal Flow Velocity
4.2.3. Analysis of the Effective Stress
4.2.4. Analysis of the Effective Strain and Extrusion Force
5. Experimental Verification
6. Conclusions
- The process of forming the axle sleeve via CWR and hot extrusion is simulated using the finite element method. The change rule of stress and strain of the billet during the forming process is shown, and the forming mechanism of the axle sleeve is revealed. The workpiece can achieve diameter compression and wall thickness reduction through high compressive stress between the die and mandrel, which is beneficial to improve the quality performance of the rolled piece.
- Through the analysis of finite element numerical simulation results combined with experimental verification, the results show the feasibility of the combined CWR and hot extrusion process for producing an axle sleeve.
- In the process of hot extrusion, the temperature of the main deformation parts of the workpiece is within the temperature range of good forming, the metal streamline is continuous and uniform, the effective stress and effective strain are not large and evenly distributed and high-quality parts can be obtained.
- The rolling force of CWR is one order of magnitude lower than the extrusion force of hot extrusion. The use of the CWR process can effectively reduce the load and weight of equipment.
- CWR can effectively improve the eccentricity of the inner hole of the billet. The internal and external steps of the axle sleeve obtained through the combination of CWR and hot extrusion are formed well. The flange is well formed, and the metal streamline is continuous. The axis of the inner hole does not easily deviate, and the wall thickness is symmetrically distributed along the axis. The product quality is good, and the production efficiency is high.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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FE Parameter (Unit) | Value |
---|---|
Speed of roller (rpm) | 10 |
Initial temperature of workpiece (°C) | 1100 |
Initial temperature of tool (°C) | 20 |
Environment reference temperature (°C) | 20 |
Heat convection coefficient with air (N/s/mm/°C) | 0.02 |
Contact heat transfer coefficient (N/s/mm/°C) | 11 |
Emissivity | 0.8 |
Friction factor (workpiece and die) | 1 |
Friction factor (workpiece and guide plate) | 0.2 |
Initial element number of workpiece | 1.1 × 105 |
FE Parameter (Unit) | Value |
---|---|
Speed of the top die (mm/s) | 30 |
Initial temperature of workpiece (°C) | 1050 |
Initial temperature of the top die (°C) | 300 |
Initial temperature of the bottom die (°C) | 400 |
Environment reference temperature (°C) | 20 |
Heat convection coefficient with air (N/s/mm/°C) | 0.02 |
Contact heat transfer coefficient (N/s/mm/°C) | 5 |
Emissivity | 0.8 |
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Sun, W.; Yang, C. Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve. Metals 2023, 13, 1017. https://doi.org/10.3390/met13061017
Sun W, Yang C. Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve. Metals. 2023; 13(6):1017. https://doi.org/10.3390/met13061017
Chicago/Turabian StyleSun, Wenhui, and Cuiping Yang. 2023. "Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve" Metals 13, no. 6: 1017. https://doi.org/10.3390/met13061017
APA StyleSun, W., & Yang, C. (2023). Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve. Metals, 13(6), 1017. https://doi.org/10.3390/met13061017