Finite element modeling and analysis for the integration-rolling-extrusion process of spline shaft

An integration-rolling-extrusion process is raised for the manufacture of spline shaft in this study. First, the principle and procedures of integration-rolling-extrusion process are described. Next, the finite element model with a simplified sector blank is established to obtain a practical method for the simulation of integration-rolling-extrusion process. Through the simulation results, the plastic forming mechanisms are clearly revealed. During the integration-rolling-extrusion process, the equivalent stress, deformation degree, and material flow behavior mainly distribute on the surface layer of the blank and then gradually decrease along the radial inward direction. In the core region of the blank, there are almost no effective stress distribution, deformation degree, and material flow behavior. Next, the experiments are carried out on a specialized forming equipment to verify the finite element model. The results are measured and compared with finite element results. The finite element results show a good agreement with experiments; thus, the finite element analysis on the integration-rolling-extrusion process is credible. In addition, the measurement results show that the dimensions meet the requirement of heavy truck application. It indicates that the integration-rolling-extrusion process is feasible for the manufacture of spline shaft. However, the surface quality of the formed spline shaft is not satisfying, which needs to be discussed further.