内外局部约束下内齿圈滚轧成形

A new efficient rolling method with internal and external local constraints for manufacturing inner ring gear has been developed in this study. The frame of the new rolling process has been constructed, and the motion characteristics of inner rolling die, outer rolling die and workpiece are analyzed. The experimental platform with two pairs of rolling dies is developed, and the rolling process of inner ring gear was implemented. The finite element (FE) model of the rolling process with internal and external local constraints for inner ring gear is developed, and the finite element analyses with two pairs and three pairs of rolling dies are carried out. The experimental and FE results indicated that the profile of inner gear is full and clear, and the height of inner gear meets designed height, so the proposed rolling process of inner gear is feasible. Compared with the height of inner gear obtained by experiment, predictive error of FE model is less than 5%. By means of proper adjustments for geometries of die and billet, the rolled height of inner gear can be controlled and the forming quality of end of inner gear can be improved. The results provide a theoretical basis and useful guideline for manufacturing inner complex-profile part with high efficiency and saving force.