Manufacturing large shafts by a novel flexible skew rolling process

When manufacturing large shafts with multi-specification and small-batch production, both the conventional forging rolling process bring a high tooling cost due to heavy press or large-sized specialized roller. In this study, novel flexible skew (FSR) is proposed by adding degrees of freedom rollers as compared typical process. Since each FSR has three (circle rotating, radial feeding), can be divided into four stages: rolling, inclining, leveling. Therefore, produce various same via programming different movements. To verify feasibility process, physical investigation corresponding numerical simulation for single-step shaft undertaken Φ80 × 390 mm C45 steel billet. According results from experiments simulations, formed maximum deviation 0.99 mm, its microstructure properties have been improved obviously. Moreover, although there tendency center crack in products predicted results, transverse longitudinal sections are free central cracking. The major forming defects that existed on rolled knurled pockmarks, surface threads, side cavity, which cross-wedge removed machining. authors’ knowledge, good combination production less loading, will great engineering significance reduce manufacturing.