Springer Nature is making SARS-CoV-2 and COVID-19 research free. View research | View latest news | Sign up for updates

Deformation characteristic of thread and spline synchronous rolling process

Abstract

In the thread and spline synchronous rolling (TSSR) process, the thread rolling deformation couples with the spline rolling deformation. The deformation behavior in the synchronous rolling process is very complex due to multi-die constraint, multi-axes motion, and multi-parameter association. Exploring the deformation characteristics in the TSSR process is important for parameter optimization and process control of the TSSR process. In this paper, the finite element method (FEM) was adopted to investigate the deformation in the TSSR process. The data were extracted from FE code DEFORM and were processed in code MATLAB. The deformation characteristics in the TSSR process were studied by mean of analyzing displacement, strain, and invariants of deviatoric stress tensor. The results in the present study indicated that: direction of rotation of workpiece has an influence on the direction of axial displacement in cores of threaded section and splined section; the influence of tooth profiles (such as threaded profile, splined profile) on the TSSR process only presents in the superficial zone; the deformation-affected region along radial direction in the threaded section is larger than that in the splined section; the deformation in the threaded section and splined section has little influence on axial regions.

This is a preview of subscription content, log in to check access.

References

  1. 1.

    Zhang DW, Zhao SD (2014) New method for forming shaft having thread and spline by rolling with round dies. Int J Adv Manuf Technol 70:1455–1462

  2. 2.

    Zhang DW, Zhao SD (2015) Discussion of plastic forming for roller in PRSs. China Mech Eng 26(3):385–389 (in Chinese)

  3. 3.

    Zhang DW, Zhao SD, Wu SB, Zhang Q, Fan SQ, Li JX (2015) Phase characteristic between dies before rolling for thread and spline synchronous rolling process. Int J Adv Manuf Technol 81:513–528

  4. 4.

    Domblesky JP, Feng F (2001) Finite element modeling of external threading rolling. Wire J Int 34(10):110–115

  5. 5.

    Domblesky JP, Feng F (2002) Two-dimensional and three-dimensional finite element models of external thread rolling. Proc Inst Mech Eng Part B J Eng Manuf 216:507–509

  6. 6.

    Neugebauer R, Putz M, Hellfritzsch U (2007) Improved process design and quality for gear manufacturing with flat and round rolling. Ann CIRP 56(1):307–312

  7. 7.

    Kamouneh AA, Ni J, Stephenson D, Vriesen R (2007) Investigation of work hardening of flat-rolled helical-involute gears through grain-flow analysis, FE-modeling, and strain signature. Int J Mach Tool Manuf 47:1285–1291

  8. 8.

    Zhang DW, Li YT, Fu JH, Zheng QG (2007) Mechanics analysis on precise forming process of external spline cold rolling. Chin J Mech Eng 20(3):54–58

  9. 9.

    Zhang DW, Li YT, Fu JH, Zheng QG (2009) Rolling force and rolling moment in spline cold rolling using slip-line field method. Chin J Mech Eng 22(5):688–695

  10. 10.

    Yang H, Zhan M, Liu YL, Xian FJ, Sun ZC, Lin Y, Zhang XG (2004) Some advanced plastic processing technologies and their numerical simulation. J Mater Process Technol 151:63–69

  11. 11.

    Zhu S, Yang H, Guo L, Hu L, Chen X (2014) Research on effects of coordinate deformation on radial-axial ring rolling process by FE simulation based on in-process control. Int J Adv Manuf Technol 72:57–68

  12. 12.

    Han X, Hua L, Wang X, Zhou G, Lu B (2014) Ring blank design and its effect on combined radial and axial ring rolling. Int J Adv Manuf Technol 72:1161–1173

  13. 13.

    Lin JC (2002) Prediction of rolling force and deformation in three-dimensional cold rolling by using the finite-element method and a neural network. Int J Adv Manuf Technol 20:799–806

  14. 14.

    Hwang YM, Hwang KN, Chang CY (2013) Manufacture of magnesium alloy screws. Int J Adv Manuf Technol 68:1285–1292

  15. 15.

    Takeda T, Nasu Y (1991) Evaluation of yield function including effects of third stress invariant and initial anisotropy. J Strain Anal Eng Des 26(1):47–53

  16. 16.

    Wang ZR (1989) Fundamental of Plastic Working Mechanics. National Defence Industry Press, Beijing (in Chinese)

  17. 17.

    Li F, Yuan SJ, Liu G, He ZB (2008) Research of metal flow behavior during extrusion with active friction. J Mater Eng Perform 17(1):7–14

  18. 18.

    Li F, Wang LL, Yuan SJ, Wang XS (2009) Evaluation of plastic deformation during metal forming by using lode parameter. J Mater Eng Perform 18(9):1151–1156

  19. 19.

    Kobayashi S, Oh SI, Altan T (1989) Metal forming and the finite-element method. Oxford University Press, New York

  20. 20.

    Zhang DW, Yang H (2015) Analytical and numerical analyses of local loading forming process of T-shape component by using Coulomb, shear and hybrid friction models. Tribol Int 92:259–271

  21. 21.

    DEFORMTM (2011) Integrated 2D-3D Version 10.2 and DEFORMTM v11.0 (Beta) User’s Manual. Scientific Forming Technologies Corporation, Columbus

  22. 22.

    Zhang DW, Zhao SD, Li YT (2014) Rotatory condition at initial stage of external spline rolling. Math Prob Eng 2014: Article ID 363184, 12 pages

  23. 23.

    Li YT, Song JL, Zhang DW, Zheng QG (2008) Mechanics analysis and numerical simulation on the precise forming process of spline cold rolling. Mater Sci Forum 575–578:416–421

  24. 24.

    Zhang DW (2007) Theoretical research on process of spline cold rolling. M.S. thesis, Taiyuan University of Science and Technology. (in Chinese)

  25. 25.

    Domblesky JP, Feng F (2002) A parametric study of process parameters in external thread rolling. J Mater Process Technol 121:341–349

Download references

Author information

Correspondence to Da-Wei Zhang.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Zhang, D., Zhao, S. Deformation characteristic of thread and spline synchronous rolling process. Int J Adv Manuf Technol 87, 835–851 (2016). https://doi.org/10.1007/s00170-016-8524-5

Download citation

Keywords

  • Plastic deformation
  • Synchronous rolling
  • Numerical simulation
  • Deviatoric stress invariant