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A helical rolling process for producing ball studs

Tomczak Janusz, Pater Zbigniew, Bulzak Tomasz

Archives of Civil and Mechanical Engineering

2019

Vol. 19, no. 4

1316--1326

This paper presents the numerical and experimental results of a study investigating helical rolling of ball studs. First, methods for producing balls studs widely used in the automotive industry are discussed. Then, in light of the discussed manufacturing techniques, a helical rolling process for producing this type of parts is proposed. The idea of rolling stepped parts in skew rolling mills is presented and the design concept for helical tools is described. Next, numerical results of a helical rolling process for ball studs are presented. Theoretical considerations are based on the results of simulations performed by the finite element method using the FORGE NxT simulation software. The simulations involved examining metal flow, thermal parameters and force parameters in the process, as well as predicting material cohesion loss based on the distribution of the Cockcroft-Latham ductile fracture criterion. The numerical results were verified experimentally. In the experiments, the process was investigated with respect to potential failure modes. The correctness of the designed numerical models of helical rolling was assessed based on the shape of produced forgings and the distributions of force parameters. Obtained results demonstrate that helical rolling is an effective technique for producing ball studs, and the design concept for helical tools can be based on the solutions developed for wedge tools used in cross wedge rolling.

Analiza numeryczna procesu walcowania śrubowo-klinowego odkuwki sworznia kulistego

Pater Z., Tofil A.

Hutnik, Wiadomości Hutnicze

2015

Vol. 82, nr 7

427--431

W artykule opisano przykład zastosowania nowego procesu walcowania śrubowo-klinowego do kształtowania odkuwki sworznia kulistego. Omówiono istotę tego procesu oraz narzędzia potrzebne do jego realizacji. Słuszność opracowanej koncepcji walcowania potwierdzono na podstawie wykonanej symulacji numerycznej. Przedstawiono rozkłady intensywności odkształcenia, temperatury, funkcji zniszczenia w odkuwce sworznia kulistego, jak również przebiegi sił kształtowania i momentu walcowania.

The paper describes the application of a new helical-wedge rolling process for forming a ball pin. Both the design of the process and tools for its realization are discussed. The suitability of the developed rolling technique is then verified using a numerical simulation. The distributions of effective strain, temperature and damage function in a ball pin as well as the variations in forming forces and torque are presented.