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Influence of Processing Parameters on the Thread and Spline Synchronous Rolling Process: An Experimental Study.

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The thread and spline synchronous rolling (TSSR) process can form complex parts, but parameter control is key. Optimizing geometric and motion parameters ensures dimensional accuracy and smooth rolling, achieving pitch errors under 0.5 μm.

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Mechanical Engineering

Background:

  • The thread and spline synchronous rolling (TSSR) process enables simultaneous formation of multiple profiles, ensuring positional consistency.
  • Intercoupling of multi-meshing motions and multi-deformation characteristics can lead to dimension overshoot and process instability.

Purpose of the Study:

  • To investigate the influence of controllable geometric and motion parameters on the TSSR process.
  • To identify key parameters for controlling size errors and ensuring a smooth rolling process.

Main Methods:

  • Orthogonal experimental design was employed to determine the synchronous rolling experimental scheme.
  • Geometric parameters of different tooth profiles were measured and analyzed post-rolling.

Main Results:

  • Uncoordinated meshing movement causes tooth errors in the splined section.
  • Processing parameter variations lead to size fluctuations in the splined section.
  • Billet diameter primarily affects outside diameter; pitches are sensitive to rolling die motion parameters.
  • Matching rolling die motion parameters (e.g., lower speed with lower radial feed-in) is crucial.

Conclusions:

  • Optimizing processing parameters is essential for achieving high dimensional accuracy in TSSR.
  • An appropriate combination of parameters can yield ideal dimensional accuracy, with pitch errors below 0.5 μm demonstrated.