Investigating of the production of several eccentric, non-circular cross sections using cross wedge rolling

该研究项目的目的是研究楔横轧同时生产多个非圆偏心截面的可能性。除了同时产生不同的横截面外，还检查了成形截面的取向以及工艺的极限，超过该极限，由于偏心椭圆横截面的转变或表达而导致的横楔轧制不再可能。首先，检查椭圆横截面的产生。通过仅在径向方向对材质进行局部变形，横截面面积保持不变。椭圆截面的最大表达式，即最薄直径与最厚直径之比，是研究的一部分。除了最大值表达式外，还将研究具有多个椭圆截面的零件的成形行为。研究的另一个重点是两个椭圆截面的方向。不同的取向会对构件的不同位置产生不同的力效应。为了保持工艺的稳定性，需要考虑不同取向型材的接触点。第二个目标是研究楔横轧生产偏心型材。偏心台阶采用圆形进行。在椭圆形的研究中，横截面面积保持不变，因此材料只能径向成形。首先，检查最大可能的偏心距。作为进一步的研究，对两个偏心截面的取向进行了类似于椭圆截面的研究。第三个目的是研究椭圆截面和偏心截面的组合。在前人研究的基础上，我们将探索将两种工艺相结合以生产多个非圆偏心截面的可能性。首先采用有限元方法进行研究，以降低模具成本。利用有限元分析结果，设计出模块化刀具。使用该工具，可以研究不同的参数组合。

The aim of the proposed research project is to study the possibilities of cross wedge rolling for the simultaneous production of several non-circular eccentric cross sections. In addition to the simultaneous generation of different cross sections the orientation of the formed sections is examined as well as the limits of the process, beyond which a cross-wedge rolling due to the transitions or expressions of eccentric elliptical cross sections is no longer possible.First, the production of elliptical cross sections is examined. By locally deforming the material only in radial orientation the cross section area remains constant. The maximum expression of the elliptical cross section, the ratio of the thinnest to thickest diameter, is part of the investigations. In addition to the maximum expression, the forming behavior of the part with several elliptical cross sections will be studied. Another main point of the investigations is the orientation of two elliptical sections to each other. Different orientation results in different force effects affecting on different positions of the component. In order to keep the process stable, the contact point for the different oriented sections needs to be considered.The second aim is to study the production of eccentric sections using cross wedge rolling. The eccentric steps are carried out with a circular shape. As well as within the elliptical investigations, the cross section area stays constant so that material is only formed radial. First, the maximum possible eccentricity is examined. As a further investigation, the orientation of two eccentric sections to each other is examined similar to the studies of the elliptical cross-section.The third aim is to study the combination of elliptical and eccentric sections. With the knowledge gained from the previous studies the possibilities of combining both processes in order to produce several sections with non-circular eccentric cross sections will be investigated.The investigations are carried out first using FEM to reduce tooling costs. Using the FEM results, a modular tool will be designed. With this tool, investigating different parameter combinations are possible.