Numerical Simulation And Process Research On Rolling For Preform Of Pole Piece

Pole piece is a key part of electrical motor, it is an expanded part which is near the rotor of main pole. The role of pole piece is to reduce the reluctance of air-gap, improve the main magnetic field distributions and fix the excitation windings. Pole piece formed by three circular surfaces, the shape is complex and require high surface quality and dimensional accuracy. The traditional forming methods of pole piece are machining, powder metallurgy, forging, etc., the shortcomings of them are low material utilization, poor quality.Therefore, it is necessary to explore new process to forming the parts. As one part of special rolling, part rolling has the advantage of low load, high efficiency, and high precision, it is suitable for high volume production of mechanical parts. By taking preformed pole piece as research object, the paper analyzed its forming process and carried out the rolling process of preform for pole piece.During the study of preform process, through analysis of the characteristics of the pole piece, we designed two programs rolling process and molds, get the size of the original stock by theoretical calculation. We used bulk forming finite element analysis software DEFORM-3D to simulate the rolling process of pole piece preform. According to the simulation, it carried out the metal flow law, the stress and strain field, and load prediction. The result shows that the optimized parameters for the process are as follows:blank sizeφ18-100mm, speed of roller 36r/min, first press quantity 6mm, and friction coefficient 0.5. In the simulation analysis, the paper discussed the issue of anterior wall forming and proposed improvement measures.We plan to make experiments on Z28-80-type rolling machine, in view of the existing equipment can not meet the test requirement, Z28-80-type rolling machine was modified in this paper to make it preform rolling equipment. The core is a set of transmission, it consists of bracket, gears, shafts, bearings,bearing covers and other components. Through the structure, thread rolling machine opposite the output shaft rotation and got the function of rolling. We obtain the distribution of force and deformation by using finite element analysis software ANSYS to analysis its static. A physical experiment was carried on the rolling equipment. Through physical experiments and numerical simulations, we verified the reliability by comparing numerical simulation and physical experiment. Theory and experiment show that the rolling process can be used to forming pole piece.