Abstract
A novel metal plastic forming technology, namely rotary forging with double symmetry rolls (DSRs) is presented in comparison to more conventional single roll rotary forging. Based on a reliable three-dimensional elastic–plastic dynamic explicit finite element model, the fundamental deformation characteristics of cold rotary forging with DSRs of a cylindrical workpiece are made clear. Meanwhile, the interactive effects of two main processing parameters, feedrate v of the lower die and rotational speed n of the two upper dies on the forming process have been comprehensively revealed. As a specific case, hot rotary forging of a spiral bevel gear was analysed and an experiment was carried out on a developed hot rotary forging press with DSRs. The simulation results are in good agreement with the experimental ones and demonstrate that rotary forging with DSRs has a potential prospect in forming a complex spiral bevel gear. The results of this research help to better understand the advanced metal plastic forming technology of rotary forging with DSRs.
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