Spline Cold Forming Theory And Simulation Research

Cold metal volume-forming is a kind of high efficient，precision plasticforming technology. It has a series of advantages，such as high formingprecision， good mechanical properties， high productivity， high materialutilization，energy saving and environment protection. Therefore, it is suitablefor mass production，liable to reduce cost，and is a kind of green manufacturingtechnology.As a kind of new type precision cold volume forming technology, splinecold-rolling is also a kind of less cutting advanced manufacturing technology. Arapid rotating die is used to impact the workpiece repeatedly and plasticdeformation is formed under room temperature, until spline shafts with the sameoutline of the dies is formed. This technology has the advantages，such as higherproductivity，less energy consumption，less material costing，nice surface qualityand good mechanical properties. It can satisfy the higher strength and higherprecision requirements of market for the spline shaft products. In addition，thetechnology of rapid spline cold-rolling conforms to the development needs ofhigh efficiency， low carbon costing and environment protecting inmanufacturing，and it has a good development prospects.The rules of stress and strain of metals on the impacting loads, the strainratios, inertial effect and influence of the transmission of stress wave on the coldrolling forming process were studied. The factors affecting the forming qualitieswere analyzed. According to the characteristic of the process in which therolling wheel impacts the workpiece intermittently, the influence of the rollingwheel on the deformation of the workpiece was analyzed, category of the rollingwheel velocity was determined. The stress and strain stations and the force ofthe cold rolling process was analyzed using metal plastic forming theory. Undercertain giving assumptions, the reaction force of the rolling wheel on theworkpiece can be considered to be the stack up of dynamic force() whichcaused by inertial effect and static() foece which caused by strength effect ofmaterials；the dynamic and static force and the stress and strain of micro element during one rapid impact on the workpiece were analyzed. Finally，based on Finite element elastic-plastic theory, the stress-strain regularity, theflow rules of metal, the influence of different processing parameters and theforming defect during rapid cold-rolling of spline were analyzed usingDeform-3D finite element simulation software and method.