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花键轴增量式滚轧成形坯料直径计算及有限元分析.docx

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花键轴增量式滚轧成形坯料直径计算及有限元分析 Introduction Rollingisawidelyusedmetalformingprocessthatinvolvesreducingthethicknessofamaterialbypassingitbetweenasetofrotatingrolls.Theprocesscanbeusedtoproducematerialsofvariousshapes,sizes,andthicknesses,suchassheets,plates,bars,andwires.Thequalityandefficiencyoftherollingprocessdependonseveralfactors,includingthetypeandqualityoftherolls,thematerialbeingrolled,andthelubricationmethodused.Oneofthecriticalfactorsintherollingprocessisthediameteroftheinitialbilletorpreform. Inthispaper,wewilldiscussthecalculationandfiniteelementanalysisofthediameterofbilletsformedbyincrementallyrollingwithaflowerkeyaxis.Thisprocessinvolvesusingasetofrollswithaspecificprofiletoincrementallyreducethediameterofapreform,resultinginafinalproductwithhigherqualityandtightertolerances. Methodology Tocalculatethediameterofthebilletformedbyincrementallyrollingwithaflowerkeyaxis,wefirstneedtodeterminethereductionratioofeachpassandthenumberofpassesrequiredtoachievethedesireddiameter.Thereductionratioistheratioofthethicknessofthepreformtothethicknessoftheproductaftereachpass.Typically,thereductionratiorangesfrom5%to20%,dependingonthematerialbeingrolledandthedesiredfinalthickness.Thenumberofpassesrequiredcanbecalculatedusingtheformula: N=(log(D1/D2))/log(R) WhereNisthenumberofpasses,D1istheinitialdiameter,D2isthefinaldiameter,andRisthereductionratio.Oncewehavedeterminedthenumberofpassesrequired,wecanusetheflowerkeyaxisprofiletocalculatethediameterofthebilletaftereachpass.Theflowerkeyaxisprofileisacomplexshapethatinvolvesmultiplecurvesandanglesandrequiresadvancedmathematicalmodelingtocalculateaccurately. FiniteElementAnalysis Finiteelementanalysis(FEA)isapowerfultoolusedinengineeringandmanufacturingtosimulateandanalyzethebehaviorofcomplexstructuresandsystemsundervariousconditions.Inthecaseofincrementalrolling,FEAcanbeusedtomodelthedeformationofthepreformandtheforcesactingontherollsduringtherollingprocess.Thisinformationcanthenbeusedtooptimizetheprocessandimprovetheefficiencya