Abstract
The study presents a selection of numerical and experimental results of producing hollow stepped shafts. The first part of this study describes the advantages of using hollow parts in machine design and discusses the main fields of their applications. Next, an innovative rotary compression method for producing stepped axes and shafts is proposed. In order to estimate the technological potential of rotary compression, we performed comprehensive numerical and experimental analyses of producing hollow stepped shafts by this new technique. First, the rotary compression process for hollow parts was modeled numerically by the finite element method. The 3D modeling was made using the Simufact Forming software. The numerical results were then verified by experimental tests conducted under laboratory conditions. The experiments were performed using a machine designed by the authors of the present study. The following variables were investigated in the experiments: the effect of billet wall thickness on the process, the quality and geometry of products, and variations in loads and torques. The experimental results confirm that rotary compression can be used to produce hollow stepped shafts with a wide range of thicknesses.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Piwek V, Kuhfuss B, Moumi E, Hork M (2010) Light weight design of rotary swaged components and optimization of the swaging process. Int J Mater Form 3:845–848
Tomczak J, Pater Z, Bulzak T (2013) Effect of technological parameters on the rotary compression process. Eksploatacja i Niezawodnosc – Maint Reliability 15:279–283
Kettner P, Schmieder F (1997) Manufacturing of hollow transmission shaft via bulk – metal forging. J Mater Process Technol 71:113–118
Lim S-J, Choi H-J, Lee C-H (2009) Forming characteristics of tubular product through the rotary swaging process. J Mater Process Technol 209:283–288
Groche P, Fritsche D (2006) Application and modelling of flow forming manufacturing processes for internally geared wheels. Int J Mach Tools Manuf 46:1261–1265
Zhang Q, Wu C, Zhao S (2012) Less loading tube-hydroforming technology on eccentric shaft part by using movable die. Mater Trans 53:820–825
Yamanaka S, Kazama T, Dohi M (2005) Hollow stepped shaft and method of forming the same. United States Patents No. US 2005/0016246
Urankar S, Lovell M, Morrow C, Kawada K (2006) Establishment of failure conditions for the cross-wedge rolling of hollow shafts. J Mater Process Technol 177:545–549
Neugebauer R, Kolbe M, Glass R (2001) New warm forming processes to produce hollow shaft. J Mater Process Technol 119:277–282
Tomczak J, Pater Z, Bulzak T (2015) Forming of hollow shaft forging from titanium alloy Ti6Al4V by means of rotary compression. Arch Metall Mater 60:419–425
Qin Y, Ma Y, Balendra R (2004) Pressurising materials and process design considerations of the pressure-assisted injection forging of thick-walled tubular components. J Mater Process Technol 150:30–39
Bartnicki J, Pater Z (2005) The cross-wedge rolling process of hollowed parts. Lublin University of Technology Press, Lublin
Pater Z, Bartnicki J (2006) Wedge-rolls rolling of hollowed parts. J Achiev Mater Manuf Eng 18:407–410
Urankar S, Lovell M, Morrow C, Li Q, Kawada K (2006) Development of a critical friction model for cross wedge rolling hollow shafts. J Mater Process Technol 177:539–544
Neugebauer R, Glass R, Kolbe M, Hoffmann M (2002) Optimisation of processing routes for cross rolling and spin extrusion. J Mater Process Technol 125–126:856–862
Bartnicki J, Tomczak J, Pater Z (2015) Numerical analysis of the cross-wedge rolling process by means of three tools of stepped shafts from aluminum alloy 7075. Arch Metall Mater 60:433–435
Bartnicki J, Pater Z (2005) Numerical simulation of three-rolls cross wedge rolling of hollowed shaft. J Mater Process Technol 164–165:1154–1159
Pater Z, Tomczak J (2013) Method for plastic forming of toothed shafts. European patent no. EP 2422898
Pater Z, Tomczak J (2013) Rotary compression of hollow parts by cross rolling. European patent no. EP 2422896
Ji H, Liu J, Wang B et al (2015) Cross-wedge rolling of a 4Cr9Si2 hollow valve: explorative experiment and finite element method simulation. Int J Adv Manuf Technol 77:15–26
Pater Z, Gontarz A, Tomczak J, Bulzak T (2015) Producing hollow drive shafts by rotary compression. Arch Civil Mech Eng. doi:10.1016/j.acme.2014.10.002
Tang H, Hao C, Jiang Y et al (2010) Forming process and numerical simulation of making upset on oil drill pipe. Acta Metall Sin 23:72–80
Semiatin, S.L. (ed) (1990) ASM Handbooks. Metalworking: bulk forming, Volume 14A. ASM International, USA
Lipski T (1979) Rotary swaging. WNT, Warsaw
Orban H, Hu SJ (2007) Analytical modeling of wall thinning during corner filling in structural tube hydroforming. J Mater Process Technol 194:7–14
Dabrowski Z, Maksymiuk M (1984) Shafts and axles. Polish Scientific Publishers, Warsaw
Simufact Engineering (2012) Simufact.material 2012. 0.0.14871. Simufact engineering gmbh, Hamburg
Pater Z, Gontarz A, Weroński W (2001) Selected problems of the theory and technology of cross-wedge rolling. Polish Scientific Society, Lublin
Pater Z, Tofil A (2007) Experimental and theoretical analysis of the cross–wedge rolling process in cold forming conditions. Arch Metall Mater 52:289–297
Hana H-N, Kim K-H (2003) A ductile fracture criterion in sheet metal forming process. J Mater Process Technol 142:1231–1238
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Tomczak, J., Pater, Z. & Bulzak, T. The influence of hollow billet thickness in rotary compression. Int J Adv Manuf Technol 82, 1281–1291 (2016). https://doi.org/10.1007/s00170-015-7437-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7437-z