In a significant advancement for the construction and manufacturing sectors, research led by Jiang Yang from the Transportation Institute at Inner Mongolia University has unveiled promising insights into the production of thick-walled hollow shafts using cross wedge rolling (CWR). This innovative approach addresses the growing demand for lightweight mechanical structures, which are increasingly critical in industries such as automotive and machinery.
Traditional methods of manufacturing hollow shafts, including cutting and die forging, have long been criticized for their inefficiencies and low material utilization. With the industry’s shift towards more sustainable practices and the need for enhanced productivity, CWR emerges as a game-changer. “Cross wedge rolling not only improves productivity but also enhances product quality while significantly reducing material and energy consumption,” Jiang notes, emphasizing the technology’s potential to streamline manufacturing processes.
The research specifically investigates the roundness error phenomenon that often hampers the formation of thick-walled hollow shafts. Through meticulous hot compression tests on the alloy steel 25CrMo4, Jiang and his team developed a finite element simulation model using Deform-3D. This model allowed them to analyze how various factors—such as area reduction, forming angle, and stretch angle—affect roundness error during the rolling process.
The findings are compelling. The study indicates that a larger area reduction correlates with a smaller roundness error, while increasing the forming angle also contributes to improved outcomes. Conversely, a greater stretch angle tends to increase roundness error, a challenge that can be mitigated by raising the rolling temperature. “Our simulations reveal a clear relationship between process parameters and roundness error, which can guide future manufacturing practices,” Jiang explained.
The implications of this research extend beyond theoretical advancements; they promise substantial commercial impacts. By optimizing the production of hollow shafts, manufacturers can expect not only to enhance efficiency but also to reduce waste—aligning with global sustainability goals. This could lead to lower costs and faster production times, giving companies a competitive edge in an increasingly demanding market.
As industries continue to evolve, the insights from Jiang’s research, published in the Journal of Engineering Science, could pave the way for innovative manufacturing techniques that redefine how hollow components are produced. The potential for reduced costs and improved product quality could well reshape the landscape of construction and machinery manufacturing, making this research a pivotal point in the ongoing quest for efficiency and sustainability in engineering practices.
For more information on Jiang Yang and his work at the Transportation Institute, visit lead_author_affiliation.
