The cold semi-precision forging of a multi-row sprocket was investigated using upper-bound （UB） and finite element methods combined with experiments. Based on the design of a new tooth profile for the sprocket, a co...The cold semi-precision forging of a multi-row sprocket was investigated using upper-bound （UB） and finite element methods combined with experiments. Based on the design of a new tooth profile for the sprocket, a cold semi-precision forging process and a kinematically admissible velocity field for filling the die cavity were proposed. Using the UB method, the velocity fields of the sprocket billet in the forming process were divided theoretically and calculated. The process of forging a multi-row sprocket was simulated using the FEM package Deform-3D V6.1 to obtain the distributions of the velocity field and the effective stress field in filling the die cavity. Similar to the simulated results, the experiment on cold forging a 5052 aluminum alloy sprocket was successfully performed. By comparing the calculated （UB method）, experimental and simulated load-stroke curves, the calculated and simulated results were basically in accordance with the experimental results. The study provides a theoretical foundation for the development of the precision forging of multi-row sprockets.展开更多
For rail rolling by universal mill, a simplified three-dimensional theoretical model was built firstly. The kinematically admissible velocity field of the web, head, and base of rail was determined respectively; moreo...For rail rolling by universal mill, a simplified three-dimensional theoretical model was built firstly. The kinematically admissible velocity field of the web, head, and base of rail was determined respectively; moreover, the corresponding strain rate field and the strength of shear strain rate were obtained. Then, the plastic deformation power of corresponding deformation zone, the power consumed on the velocity discontinuity surface, and the power generated by backward slip and forward slip were proposed. According to the upper-bound method, the roiling force of horizontal roll and two vertical rolls could be obtained. For verifying the theoretical model, the universal rolling experiments of 18 kg/m light rail was accomplished in Yanshan University Rolling Laboratory, and the experimental data of 60 kg/m heavy rail universal rolling were obtained from the Anshan Iron and Steel Group Corporation. Compared with the experimental data, the theoretical results of rolling force for 18 kg/m light rail and 60 kg/m heavy rail universal rolling were somewhat greater than experimental data, but in general did not exceed them by 15%. Thus, the simplified model was reliable and feasible for presetting and optimizing the parameters of rolling technology according to the upper-bound method.展开更多
文摘The cold semi-precision forging of a multi-row sprocket was investigated using upper-bound （UB） and finite element methods combined with experiments. Based on the design of a new tooth profile for the sprocket, a cold semi-precision forging process and a kinematically admissible velocity field for filling the die cavity were proposed. Using the UB method, the velocity fields of the sprocket billet in the forming process were divided theoretically and calculated. The process of forging a multi-row sprocket was simulated using the FEM package Deform-3D V6.1 to obtain the distributions of the velocity field and the effective stress field in filling the die cavity. Similar to the simulated results, the experiment on cold forging a 5052 aluminum alloy sprocket was successfully performed. By comparing the calculated （UB method）, experimental and simulated load-stroke curves, the calculated and simulated results were basically in accordance with the experimental results. The study provides a theoretical foundation for the development of the precision forging of multi-row sprockets.
基金Item Sponsored by National Natural Science Foundation of China (50775196)Provincial Natural Science Foundation of Hebei Province of China(08B017)
文摘For rail rolling by universal mill, a simplified three-dimensional theoretical model was built firstly. The kinematically admissible velocity field of the web, head, and base of rail was determined respectively; moreover, the corresponding strain rate field and the strength of shear strain rate were obtained. Then, the plastic deformation power of corresponding deformation zone, the power consumed on the velocity discontinuity surface, and the power generated by backward slip and forward slip were proposed. According to the upper-bound method, the roiling force of horizontal roll and two vertical rolls could be obtained. For verifying the theoretical model, the universal rolling experiments of 18 kg/m light rail was accomplished in Yanshan University Rolling Laboratory, and the experimental data of 60 kg/m heavy rail universal rolling were obtained from the Anshan Iron and Steel Group Corporation. Compared with the experimental data, the theoretical results of rolling force for 18 kg/m light rail and 60 kg/m heavy rail universal rolling were somewhat greater than experimental data, but in general did not exceed them by 15%. Thus, the simplified model was reliable and feasible for presetting and optimizing the parameters of rolling technology according to the upper-bound method.
