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Innovative method of rolling railcar axles using segmented tool assemblies

Pater Zbigniew, Tomczak Janusz, Shu Xuedao, Li Zixuan

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 3

271--282

This paper presents a novel method for rolling railcar axles using wedge tools of considerable length (about 8 m). The tools are divided into 28 components which are mounted in a tool assembly that moves in a way resembling caterpillar drive. The advantages of the proposed method include no tool idling and relatively low forming loads. A design of a segmented rolling mill with two identical tool assemblies is presented. The feasibility of the proposed solution is verified via numerical simulations conducted in Simufact.Forming. A rolling process for producing a BA3002 type railcar axle from both a cylindrical and a rectangular billet is analysed in detail. Maps of effective strain, temperature and damage function in the workpiece are shown for both cases considered. These maps clearly show that a rail axle of good quality is obtained in both rolling processes. In addition, by analysing the forming load distributions, the power of the rolling mill drive system was also estimated, which was found to be significantly higher in the case of rolling from a rectangular billet.

Analysis and prospects of efficient and precise forming technology for aeroengine turbine shafts

Shu Xuedao, Chen Lulu, Pater Zbigniew, Li Zixuan, Jie Xuhai, Xia Yingxiang, Zhang Song, Chen Qian, Xu Yongming, Bartnicki Jarosław

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 1

132--147

The turbine shaft is a crucial core component of aeroengines, made of difficult-to-deform high-temperature alloy materials, characterized as a long hollow stepped shaft with deep internal holes. Achieving efficient, high-performance, and precise manufacturing of turbine shafts is a cutting-edge issue urgently needing resolution in the field of aeroengine manufacturing. Currently, the forming process for turbine shafts mainly involves forging the external shape, followed by machining the outer profile and drilling the internal holes, which presents problems such as low efficiency and high material consumption. This paper analyzes the principles and characteristics of advanced forming processes for shaft components, including cross-wedge rolling (CWR), three-roll skew rolling (TRSR), and piercing and cross rolling integration (PCRWI). This paper expounds the principles and characteristics of these process forming turbine shafts, concluding that an integrated short-process flexible forming method is the future development direction for precise plastic forming of aeroengine turbine shafts. The research results have significant theoretical value and practical engineering implications for enhancing the overall manufacturing capability of aeroengines.

Optimization of porthole extrusion die for 6063 aluminum alloy profile with thin‑walled multi‑cavity complex section and analysis of profile performance

Ma Zheng, Shu Xuedao, Xu Haijie, Wang Guobiao, Tong Fei, Li Zixuan, Chen Kai, Li Guoping, Li Bo

Archives of Civil and Mechanical Engineering

2024

Vol. 24, no. 2

art. no. e85, 2024

In the porthole extrusion of complex profiles, the die structure plays a significant role in the formability of the profile. In this study, numerical simulation was conducted to optimize the porthole extrusion die for a complex cross-sectional profile, with the standard deviation of velocity (SDV) as the evaluation criterion. The optimization involved the introduction of pseudo-mandrels, adjustments to the shape of the 2nd-step welding chamber, and modification of the bearing height. The rationality of the optimized die structure was verified through porthole extrusion experiments, and the microstructure and mechanical properties of the profile at different locations were investigated. The results show that the optimized die effectively controlled the metal flow velocity. The actual profiles obtained from the experiments exhibited improved surface quality and avoided defects such as distortion and dimensional errors. The grain size is uniform at different positions of the profile, and the mechanical properties are comparable. The profile meets the performance requirements. This research provides guidance for the practical production of the profiles.