scholarly journals Analysis of Metal Flow Behavior and Residual Stress Formation of Complex Functional Profiles under High-Speed Cold Roll-Beating

2018 ◽  
Vol 2018 ◽  
pp. 1-10 ◽  
Author(s):  
Fengkui Cui ◽  
Yongxiang Su ◽  
Kege Xie ◽  
Wang Xiaoqiang ◽  
Xiaolin Ruan ◽  
...  
Keyword(s):  
Residual Stress ◽  
Plastic Flow ◽  
High Speed ◽  
Metal Flow ◽  
Tooth Profile ◽  
Stress Generation ◽  
Functional Profile ◽  
Forming Process ◽  
Cold Roll ◽  
Stress Formation

To obtain a good surface layer performance of the complex functional profile during the high-speed cold roll-beating forming process, this paper analyzed the metal plastic flow and residual stress-formed mechanism by using a theoretical model of the metal flow and residual stress generation. By using simulation software, the cold roll-beating forming process of a spline shaft was simulated and analyzed. The metal flow and residual stress formation law in the motion were researched. In a practical experiment, the changes in the grains in the spline tooth profile section and the residual stress distribution on the tooth profile were studied. A microcorrespondence relationship was established between the metal plastic flow and the residual stress generation. The conclusions indicate that the rate at which the metal flow decreases changes gradually at different metal layers. The residual stress value is directly related to the plastic flow difference. As the roll-beating speed increases, the uneven degree of plastic deformation at the workpiece surface increases, and the residual stress in the tooth profile is generally greater. At the same roll-beating speed, the rate change trend of the metal flow decreases gradually from the surface to the inner layer and from the dedendum to the addendum. The residual stress distribution on the surface of the tooth profile decreases from the dedendum to the addendum. These findings provide a basis and guidance for the controlled use of residual stress, obtaining better surface layer quality in the high-speed cold roll-beating process of the complex functional profile.

scholarly journals A Model of Surface Residual Stress Distribution of Cold Rolling Spline

2017 ◽  
Vol 2017 ◽  
pp. 1-21 ◽  
Author(s):  
Z. H. Ding ◽  
F. K. Cui ◽  
Y. B. Liu ◽  
Y. Li ◽  
K. G. Xie
Keyword(s):  
Residual Stress ◽  
Cold Rolling ◽  
High Reliability ◽  
Processing Parameters ◽  
Multiple Regression Model ◽  
Tooth Profile ◽  
Contour Method ◽  
Forming Process ◽  
Surface Residual Stress ◽  
Cold Roll

Residual stress is an important parameter in the evaluation of the performance of a cold rolling spline surface. However, research on cold rolling spline is rare. To improve the surface property of a spline, an involute spline is selected as the object of this study. The contour method for determining cold roll-beating residual stress involves measuring the force spatial distribution, performing a statistical analysis of the experimental results, establishing the parameters for the tooth profile for different positions (dedendum, pitch, and addendum) of residual stress, and determining the effect of pressure on the relationship between stress and the depth of the cold roll-beating. A response surface method is used to establish the spline tooth profile of the dedendum, pitch, and addendum of the residual stress and different depths of the stress layer to obtain the parameters of a multiple regression model and perform a comparative analysis of the experimental and prediction results. Research indicates that the prediction results have high reliability. The establishment of this model has important guiding significance to control the residual stress in the cold roll-beating forming process, optimize the cold roll-beating processing parameters, and improve the surface properties of cold rolling spline.

Simulation Analysis of Metal Flow in High-Speed Cold Roll-Beating

2014 ◽  
Vol 556-562 ◽  
pp. 113-116 ◽  
Author(s):  
Feng Kui Cui ◽  
Ya Fei Xie ◽  
Xiao Dan Dong ◽  
Li Min Hou
Keyword(s):  
High Speed ◽  
Simulation Analysis ◽  
Metal Flow ◽  
Equivalent Strain ◽  
Flow State ◽  
Analysis Model ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Flow Law

In order to achieve the metal flow law in high-speed cold roll-beating, the metal flow state was analyzed on the basis of the principle of high-speed cold roll-beating and the Law of Minimum Resistance. The finite element analysis model was established based on the processing of involute spline; high-speed cold rolling forming process was simulated. The equivalent strain and the flow track of a set of nodes on the contact surface on different time are analyzed, the flow law of each node is given, and simulation analysis result is compared with theoretical analysis result.

Residual Stress Profiles in High Speed Machining and Microforming of Biodegradable Orthopedic Implants

2011 ◽  
Author(s):  
M. Salahshoor ◽  
Y. B. Guo
Keyword(s):  
Residual Stress ◽  
Surface Modification ◽  
Process Parameters ◽  
High Speed ◽  
Human Organism ◽  
Surface Zone ◽  
Forming Process ◽  
Near Surface ◽  
Stress Profiles ◽  
Surface Modification Techniques

Biodegradable magnesium-calcium alloy is an attractive orthopedic biomaterial compared to permanent metallic alloys. However, the critical issue is that magnesium-calcium alloy corrodes too fast in the human organism. Hook-shaped compressive residual stress profiles, induced by various surface modification techniques in near surface zone, are proven to slower the degradation rate. This guarantees the presence of the implant in-vivo till the metabolic reactions leading to healing are over. The knowledge on how process parameters affect residual stress profiles is fundamental in successfully engineering the implants surface. Majority of surface modification techniques fall into two broad categories of cutting and forming operations. This study investigates the effects of process parameters in high speed face milling, representing a cutting operation, and low plasticity burnishing, as a micro forming process, on residual stress and microhardness profiles.

scholarly journals Manufacture of Defined Residual Stress Distributions in the Friction-Spinning Process: Investigations and Run-to-Run Predictive Control

Metals ◽  
2022 ◽  
Vol 12 (1) ◽  
pp. 158
Author(s):  
Frederik Dahms ◽  
Werner Homberg
Keyword(s):  
Residual Stress ◽  
Predictive Control ◽  
Stress Generation ◽  
Hole Drilling ◽  
Stress Distributions ◽  
Forming Process ◽  
Hole Drilling Method ◽  
Drilling Method ◽  
Spinning Process ◽  
Flange Forming

Friction-spinning as an innovative incremental forming process enables high degrees of deformation in the field of tube and sheet metal forming due to self-induced heat generation in the forming area. The complex thermomechanical conditions generate non-uniform residual stress distributions. In order to specifically adjust these residual stress distributions, the influence of different process parameters on residual stress distributions in flanges formed by the friction-spinning of tubes is investigated using the design of experiments (DoE) method. The feed rate with an effect of −156 MPa/mm is the dominating control parameter for residual stress depth distribution in steel flange forming, whereas the rotation speed of the workpiece with an effect of 18 MPa/mm dominates the gradient of residual stress generation in the aluminium flange-forming process. A run-to-run predictive control system for the specific adjustment of residual stress distributions is proposed and validated. The predictive model provides an initial solution in the form of a parameter set, and the controlled feedback iteratively approaches the target value with new parameter sets recalculated on the basis of the deviation of the previous run. Residual stress measurements are carried out using the hole-drilling method and X-ray diffraction by the cosα-method.

An approach for analyzing and controlling residual stress generation during high-speed circular milling

2012 ◽  
Vol 66 (9-12) ◽  
pp. 1439-1448 ◽  
Author(s):  
Xiaohui Jiang ◽  
Beizhi Li ◽  
Jianguo Yang ◽  
XiaoYan Zuo ◽  
Kang Li
Keyword(s):  
Residual Stress ◽  
High Speed ◽  
Stress Generation

Shaping Parameter Control of High-Speed Cold Roll-Beating Based on Simulation and Regression Analysis

2011 ◽  
Vol 109 ◽  
pp. 517-522
Author(s):  
Ming Shun Yang ◽  
Yan Li ◽  
Qi Long Yuan ◽  
Jian Ming Zheng
Keyword(s):  
Process Parameters ◽  
High Speed ◽  
Groove Depth ◽  
Forming Process ◽  
Influence Of Process Parameters ◽  
Lead Screw ◽  
Cold Roll ◽  
Plastic Forming ◽  
Near Net Shaping ◽  
Net Shaping

High-speed cold roll-beating is a near-net shaping technology in which with the characteristic of metal plastic forming used, revolving roller with high speed is applied to roll and beat the blank shaft, then force mental to flow and form a component profile. In the forming process, matching between the process parameters and the part profile is key to implement and apply the technology. In this paper, the FEM model of the lead screw cold roll-beating forming is built, the ABAQUS software is used to simulate the forming process. Based on the simulation results, the orthogonal test is designed, influence of process parameters on groove depth and bulging height of cold roll-beating process are studied; multivariate regression models of maximum bulging height and groove depth relative to the process parameters are established, and the effectiveness of the models are verified, which is of important guiding significances for forming accurate profile of lead screw by controlling process parameters.

scholarly journals Strategies for residual stress adjustment in bulk metal forming

2021 ◽  
Author(s):  
A. Franceschi ◽  
J. Stahl ◽  
C. Kock ◽  
R. Selbmann ◽  
S. Ortmann-Ishkina ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Metal Forming ◽  
Fatigue Behaviour ◽  
Stress Generation ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Bulk Forming ◽  
Process Modification

AbstractThe family of bulk forming technologies comprises processes characterised by a complex three-dimensional stress and strain state. Besides shape and material properties, also residual stresses are modified during a bulk metal forming process. The state of residual stresses affects important properties, like fatigue behaviour and corrosion resistance. An adjustment of the residual stresses is possible through subsequent process steps such as heat treatments or mechanical surface modification technologies, like shot peening and deep rolling. However, these additional manufacturing steps involve supplementary costs, longer manufacturing times and harmful effects on the product quality. Therefore, an optimized strategy consists in a targeted introduction of residual stresses during the forming processes. To enable this approach, a fundamental understanding of the underlying mechanisms of residual stress generation in dependence of the forming parameters is necessary. The current state of the art is reviewed in this paper. Strategies for the manipulation of the residual stresses in different bulk forming processes are classified according to the underlying principles of process modification.

Study on Microstructure Evolution during the Cold Roll-Beating of 40Cr

2014 ◽  
Vol 490-491 ◽  
pp. 256-261 ◽  
Author(s):  
F.K. Cui ◽  
G.P. Yan ◽  
H. Liu ◽  
X.Q. Wang ◽  
Y.X. Li
Keyword(s):  
Microstructure Evolution ◽  
High Speed ◽  
Forming Process ◽  
Forming Mechanism ◽  
Theoretical Support ◽  
Cold Roll ◽  
Macroscopic Deformation ◽  
Micro Level ◽  
Microscopic Change ◽  
The Relationship

For revealing the forming mechanism in micro level and for establishing the relationship between macroscopic deformation and microscopic changes, impact experiment of material property is conducted under the high speed cold roll-beating condition based on the plastic deformation mechanism of metal material, Based on the Zener-Hollomon constitutive relation, the macro change model is established, and the parameters of the 40 Cr are obtained according to the experimental data. Based on the model of microstructure evolution of dislocation density, the relation between macroscopic change and microscopic change is established, which provides the theoretical support for the forming process in micro level and revels the relationship between macro deformation and micro changes in the forming process of high speed cold roll-beating.

Analysis of Lead Screw High-Speed Roll-Beating Forming

2010 ◽  
Vol 455 ◽  
pp. 151-155 ◽  
Author(s):  
Yan Li ◽  
L. Zhang ◽  
Ming Shun Yang ◽  
Qi Long Yuan
Keyword(s):  
Process Simulation ◽  
High Speed ◽  
Incremental Forming ◽  
Single Point ◽  
The Self ◽  
Forming Process ◽  
Lead Screw ◽  
Forming Technology ◽  
Cold Roll ◽  
Simulation Results

Lead screw high-speed cold roll-beating is a new single-point incremental forming technology which is die-free and unconstrained. The principle of the forming process is analyzed. Modeling, meshing and parameter selecting for forming process simulation with ABAQUS are discussed. The lead screw cold roll-beating forming process simulation is carried out; stress & strain changes and metal flowing law are analyzed. Experiments are carried out with the self-developed experimental equipment. The experimental results are consistent with the simulation results, thus the validity of the simulation and feasibility of the forming process are verified.

Simulation Study on the High-Speed Single-Point Accumulation Forming Process of Involute Spline

2010 ◽  
Vol 450 ◽  
pp. 441-444 ◽  
Author(s):  
Yan Li ◽  
Ming Shun Yang ◽  
Qi Long Yuan ◽  
Feng Kui Cui
Keyword(s):  
Process Simulation ◽  
High Speed ◽  
Single Point ◽  
Practical Application ◽  
Forming Process ◽  
Forming Mechanism ◽  
Fea Model ◽  
Forming Technology ◽  
Cold Roll ◽  
Involute Spline

The high-speed cold roll-beating technology is adopted to realize the single-point accumulation forming of involute spline. Firstly, the principle of the forming technology is analyzed. Then the FEA model of the cold roll-beating of involute spline is built, the forming process simulation is finished with the ANSYS/LS-DYNA software to obtain the stress, strain and the metal flowing law of the forming process. Finally the experiments are carried out to verify the feasibility of the simulative results. This study can provide guidance for further study of the forming mechanism and practical application of the single-point accumulation forming technology.

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