本文的目的是回顾有限元方法(FEM)在楔横轧(CWR)建模中的应用。CWR是一种制造工艺,用于生产阶梯轴和轴以及锻造零件,以便在锻压机上进一步加工。尽管CWR的概念是在140年前发展起来的,直到第二次世界大战后才在工业中使用。这是由于与楔形工具设计相关的限制以及其构造的高成本。因此,直到二十世纪末,CWR工具是由轧机制造商制造的,因为他们雇用了在CWR工艺设计方面具有丰富经验的工程师。直到FEM广泛用于CWR分析时,这种情况才发生了变化。近年来开展了大量的理论研究,他们的发现在这篇综述文章中描述。本文介绍了有效应用有限元法的九个研究领域,即:应力和应变状态;力参数;CWR中的破坏模式;材料断裂;微观结构建模;工件端部凹陷的形成;空心零件的CWR形成;有色金属材料零件的CWR形成;和新的CWR方法。最后,为了展示FEM在CWR建模中的潜力,数值模拟了制造汽车变速箱中使用的阶梯轴的CWR工艺。该数值模拟实例表明,FEM可以用于对复杂的CWR情况进行建模,这将导致未来对这种先进制造技术的兴趣与日俱增。
The aim of this article is to
review the application of the finite element method (
FEM) to cross-wedge rolling (CWR) modeling. CWR is a manufacturing process which is used to produce stepped axles and shafts as well as forged parts for further processing on forging presses. Although the concept of CWR was developed 140 years ago, it was not used in industry until after World War 2. This was due to the limitations connected with wedge tool design and the high costs of their construction. As a result, until the end of the twentieth century, CWR tools were constructed by rolling mill manufacturers as they employed engineers with the most considerable experience in CWR process design. The situation has only changed recently when
FEM became widely used in CWR analysis. A vast number of theoretical studies have been carried out in recent years, and their findings are described in this overview article. This paper describes nine research areas in which
FEM is effectively applied, namely: the states of stress and strain; force parameters; failure modes in CWR; material fracture; microstructure modeling; the formation of concavities on the workpiece ends; CWR formation of hollow parts; CWR formation of parts made of non-ferrous materials; and new CWR methods. Finally, to show the potential of
FEM on CWR modeling, a CWR process for manufacturing a stepped shaft used in car gearboxes is simulated numerically. This numerical simulation example shows that
FEM can be used to model very complex cases of CWR, which should lead to a growing interest in this advanced manufacturing technique in the future.