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

提出的研究项目的目的是研究楔横轧同时生产几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方向以及过程的极限，超过该极限，由于偏心椭圆横截面的过渡或表达而不再可能进行横楔轧制。首先，考察了椭圆截面的产生。通过仅在径向方向上对材料进行局部变形，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。研究的另一个要点是两个椭圆截面彼此的方向。不同的方向对构件的不同位置产生不同的作用力。为了保持过程的稳定，需要考虑不同定向部分的接触点。第二个目的是研究楔横轧生产偏心截面。偏心的台阶以圆形进行。以及在椭圆调查中，横截面积保持不变，使材料只形成径向。首先，检查了最大可能偏心。作为进一步的研究，两个偏心截面对彼此的方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与偏心截面的组合。利用从以前的研究中获得的知识，将这两种工艺结合起来以生产具有非圆偏心截面的几个截面的可能性将进行研究。为了降低模具成本，首先采用有限元法进行了研究。利用有限元分析的结果，设计出模块化工具。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.