Modeling and Analysis of Central Damage of Cross Wedge Rolling Railway Axles Based on Hybrid Damage Criterion

doi:10.3901/JME.2025.12.141

Abstract

Abstract: Due to the trend of central cracks in cross wedge rolling (CWR), the distributions of stress state, stress triaxiality, and temperature under conditions with and without cracks are analyzed by combining of experiments and finite element (FE) simulations, and the main factors for central damage are analyzed. A hybrid damage criterion coupling the first principal stress, maximum shear stress, average stress, stress triaxiality and deformation temperature is proposed by comprehensively considering the influential mechanism of CWR damage behavior under non isothermal and complex stress, then the central damage under different CWR parameters is predicted. The mathematical equation between central damage and CWR parameters is described by regression analysis methods, and a critical parameter window for identifying the conditions of central cracks is established. The results show that, the central material is subject to tangential and axial tensile stress, and the temperature of center material is higher than that of outer layer, so the central material is most prone to cracks. The prediction of the new criterion is consistent with the characteristic that the central damage is greater than that of the outer layer, and its damage distribution is also consistent with the actual cracking morphology of the rolled piece with a relative prediction accuracy of 1.004%. In a certain rang, the central damage decreases with the increase of forming angle, increases with the increase of spreading angle, and first increases and then decreases with the increase of reduction area. The results provide a prediction criterion and a parameter optimization method for reducing damage in cross wedge rolling shafts.

Key words: cross wedge rolling, railway shafts, central damage, hybrid damage criterion, parameter optimization

CLC Number:

TG336

LIN Longfei, WANG Baoyu, GUO Wei, PENG Wenfei, WU Xiaocheng, HUANG Minghui. Modeling and Analysis of Central Damage of Cross Wedge Rolling Railway Axles Based on Hybrid Damage Criterion[J]. Journal of Mechanical Engineering, 2025, 61(12): 141-152.

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