CN107609264B - Method for determining radial critical geometric feed amount of mandrel-free rotary swaging - Google Patents
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Abstract
The invention relates to a method for determining radial critical geometric feed amount of a coreless rod rotary swaging, which comprises the following steps: (1) determining the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod; (2) determining the relationship between the maximum deformation amount of the inner circle and the outer circle of the mandrel-free rotary forging and the radial feeding amount; (3) determining a critical geometric shape meeting the rotary swaging quality according to the geometric deformation of the rotary swaging without the core rod; (4) determining the radial critical geometric feed amount of the mandrel-free rotary swaging according to the critical geometric shape; (5) and calculating the radial critical geometric feeding amount in the rotary swaging process of the coreless rod. The invention provides a method for determining the radial critical geometric feed amount of rotary swaging of a coreless rod, which is an important means for improving the quality of the inner and outer roundness of a rotary swaging shaft product and preventing the quality defects of the inner and outer roundness, the folding defects of the rotary swaging, the crack defects of the inner surface and the like.
Description
Technical Field
The invention relates to a method for determining radial critical geometric feed amount of rotary swaging of a coreless rod, in particular to a method for determining the maximum geometric feed amount of rotary swaging forming of a hollow shaft tube with a variable cross section, a variable wall thickness and bearing complex load through geometric deformation in the rotary swaging process of the coreless rod, and belongs to the technical field of methods for determining radial feed amount of rotary swaging of the coreless rod.
Background
The rotary swaging process has the advantages of continuous fiber streamline, good surface forming quality, easy forming of variable-section variable-thickness structures, high efficiency, high material utilization rate and the like, and is one of the most advanced forming methods with the highest technical level in the manufacturing of car transmission shafts and barrels. The rotary swaging shaft rotary swaging forming comprises a drawing forming process of reducing the wall thickness and reducing the wall thickness of a core rod with the same cross section and a radial flowing process of changing the wall thickness and reducing the wall thickness of a coreless rod with a variable cross section. In the rotary forging process of the core rod, because the inside and the outside of the supporting blank of the core rod are pressed, the rotary forging roundness is easy to ensure and is generally single-pass radial feeding; the outer surface of the rotary-forging blank without the mandrel is pressed, the inner surface of the rotary-forging blank without the mandrel is pulled and naturally formed, a variable-section and variable-wall-thickness structure can be formed, and a decreasing multi-pass radial feeding mode is mostly adopted. The determination of the radial feeding amount of the rotary swaging of the coreless rod is the key point and difficulty of the determination of the technological parameters of the rotary swaging feeding.
The radial feeding amount of the rotary swaging of the coreless rod not only affects the quality of the inner and outer roundness of the rotary swaging shaft, but also affects the defects of folding, inner surface cracks and the like in the rotary swaging process of the coreless rod, and particularly the folding defect of the inner circle of the rotary swaging of the coreless rod can seriously affect the static strength, the fatigue strength and the fatigue life of a rotary swaging shaft product. Therefore, the radial maximum geometric critical feeding amount in the swaging process needs to be determined through the elastic-plastic geometric deformation in the coreless bar swaging process, and the determination of the radial critical geometric feeding amount in the coreless bar swaging is an important means for improving the quality of the inner and outer roundness of the swaged shaft product and preventing the quality defects of the inner and outer roundness, the swaging folding defects, the inner surface crack defects and the like.
Disclosure of Invention
The invention provides a method for determining the radial critical geometric feed amount of rotary swaging of a coreless rod, which is an important means for improving the quality of the inner and outer roundness of a rotary swaging shaft product and preventing the quality defect of the inner and outer roundness, the folding defect of the rotary swaging, the crack defect of the inner surface and the like.
In order to achieve the purpose, the technical scheme of the invention is as follows: a method for determining radial critical geometric feed amount of a coreless rod rotary swaging comprises the following steps:
(1) determining the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod
In the rotary forging process of the coreless rod, the die moves radially to forge the blank of the rotary forging shaft, and the variable cross section and the variable wall thickness of the blank are determined by the die structure; the blank also needs to be fed in the circumferential direction after the radial feeding, and the rotary swaging of the coreless rod is alternately carried out between the radial feeding and the circumferential feeding; after the structures and the sizes of the die and the blank are determined, the rotary swaging deformation and the maximum deformation position of the blank can be determined by rotary swaging radial feeding, the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod are determined by an elastoplastic finite element simulation method, and the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod are determined by simulation under the condition that the rotary swaging radial feeding amount of the coreless rod is certain;
(2) determining the relationship between the maximum deformation amount of the inner circle and the outer circle of the mandrel-free rotary forging and the radial feed amount
The maximum deformation of the inner and outer circles of the mandrel-free rotary forging is simulated by setting different radial feeds through an elastic-plastic finite element simulation method, and then the change curve relation between the maximum deformation of the inner and outer circles of the mandrel-free rotary forging and the radial feed is established;
(3) determining critical geometric shape for guaranteeing rotary swaging quality according to geometric deformation of mandrel-free rotary swaging
The mandrel-free rotary swaging presents different geometric deformation shapes when different radial feeding amounts are adopted, the mandrel-free rotary swaging presents three shapes from circle to convex to critical to concave along with the gradual increase of the radial feeding amount, and the boundary shape of the convex deformation and the concave deformation is the critical geometric shape of the mandrel-free rotary swaging, which is the critical geometric shape for ensuring and meeting the mandrel-free rotary swaging quality;
(4) determining radial critical geometric feed amount of mandrel-free rotary swaging according to critical geometric shape
By applying an elastic-plastic finite element simulation method, by researching and calculating the deformation shape and the deformation characteristics of the mandrel-free rotary swaging, the corresponding relation between the maximum rotary swaging deformation and the critical radial feed of the mandrel-free rotary swaging geometry when the inner and outer circles of the mandrel-free rotary swaging are in the critical rotary swaging geometry is obtained through simulation;
(5) calculation process of radial critical geometric feed amount in coreless rod rotary forging process
The rotary swaging process of the coreless rod is a process that the inner diameter and the outer diameter of a blank are continuously reduced and the wall thickness is continuously increased, along with the proceeding of the rotary swaging process of the coreless rod, the outer diameter of the blank is continuously reduced, the contact area of the blank and a die can be continuously changed, the rotary swaging deformation shape and the maximum deformation position can be changed along with the reduction of the outer diameter of the blank, and the radial critical geometric feeding amount of the rotary swaging of the coreless rod can also be changed along with the reduction of the outer diameter of the blank. Therefore, the radial feeding amount of each-pass mandrel-free rotary swaging needs to be recalculated and determined, the rotary swaging deformation shape and the maximum deformation amount need to be recalculated, the critical geometric shape and the critical deformation amount are determined, and finally the radial critical geometric feeding amount of the subsequent-pass mandrel-free rotary swaging is determined according to the relationship between the rotary swaging deformation amount and the rotary swaging radial feeding amount.
The blank of the rotary swaging shaft is a seamless steel pipe with equal section and equal wall thickness, the outer diameter is 37mm, the wall thickness is 5mm, the length is 357mm, and the material characteristics of the blank are that the yield strength is less than 400MPa, the tensile strength is less than 630MPa, and the surface hardness is less than 190 HV.
In the step 1, elastic-plastic finite element simulation shows that the radial feed amount of a typical coreless rod is 0.3mm, the adopted die and the blank have symmetry, the rotary swaging deformation of the inner circle and the outer circle of the coreless rod rotary swaging also presents symmetry, and the symmetry axes are straight lines of 0 degree, 45 degrees, 90 degrees and 135 degrees; the maximum deformation position of the inner circle and the outer circle of the coreless bar swaging is at 45 degrees, 135 degrees, 225 degrees and 315 degrees, and the minimum deformation position is at 0 degrees, 90 degrees, 180 degrees and 270 degrees.
In the step 2, when the radial feeding amounts of the mandrel-free rod are respectively 0.2 mm, 0.3mm, 0.5mm, 0.6 mm and 0.7mm through elastic-plastic finite element simulation, a curve relation of the maximum deformation amounts of the corresponding inner circle and the outer circle under different radial feeding of the mandrel-free rotary swaging is established, and then the maximum deformation amounts of the inner circle and the outer circle under any radial feeding can be solved by utilizing a mathematical interpolation and extrapolation method.
In step 4, by using an elastic-plastic finite element method, when the radial feed amount of the blank of the rotary swaging shaft is 0.55mm, the rotary swaging deformation basically presents a critical geometric shape, at the moment, the maximum deformation amount is about 0.33mm, and the geometric critical radial feed amount of the rotary swaging without the mandrel is 0.55 mm.
The invention has the beneficial effects that:
the method for determining the critical geometric radial feed amount of the rotary swaging of the coreless rod determines the maximum radial geometric critical feed amount of the rotary swaging shaft through the elastic-plastic geometric deformation in the rotary swaging process of the coreless rod, solves the problem of determining the radial critical geometric feed amount of the coreless rod, and determines the radial critical geometric feed amount of the coreless rod, which is an important means for improving the quality of the inner and outer roundness of a rotary swaging shaft product and preventing the quality defects of the inner and outer roundness, the folding defects of the rotary swaging, the crack defects of the inner surface and the like.
Drawings
FIG. 1 is a view showing the feeding process of the rotary swaging of a coreless rod, the contact between the die and the blank;
(a) front view, (b) side view, (c) contact state of the die and the blank;
FIG. 2 is a schematic view of the inner and outer circular deformations and extreme deformation positions of a coreless bar swage;
(a) the outer circle deformation and ultimate deformation positions, (b) the inner circle deformation and ultimate deformation positions;
FIG. 3 is a graph showing the relationship between the maximum deformation of the inner and outer circles and the radial feed amount;
(a) a relation graph between the maximum deformation of the outer circle and the radial feed amount, and (b) a relation graph between the maximum deformation of the inner circle and the radial feed amount;
FIG. 4 is a schematic view of a swaged shape;
(a) convex, (b) critical, (c) concave;
figure 5 is a block flow diagram of a method for determining radial critical geometry feed for a coreless rod swaging process of the present invention.
Detailed Description
The invention is further described with reference to the following figures and examples.
Example (c):
the material is 25CrMo4, which is used for rotary swaging of constant-speed universal transmission intermediate shaft of a certain car and is manufactured by rotary swaging a seamless steel pipe with uniform cross section and equal wall thickness without a mandrel and with a mandrel. In the rotary swaging process of the coreless rod, the die 1 moves radially to forge the blank 2, the variable cross section and the variable wall thickness are determined by the die structure, the blank 2 moves circumferentially to perform circumferential feeding, and radial feeding and circumferential feeding are performed alternately, and the rotary swaging feeding process of the coreless rod and the die structure are shown in figures 1 (a), (b) and (c).
The original blank of the swage shaft is a seamless steel pipe with a constant cross section and a constant wall thickness, and has an outer diameter of 37mm, a wall thickness of 5mm and a short axis length of 357 mm. The material characteristics of the blank are respectively yield strength less than 400MPa, tensile strength less than 630MPa and surface hardness less than 190 HV.
The method for determining the critical geometric radial feed amount of the rotary swaging of the coreless rod comprises the following steps:
1. determining the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod
In the rotary forging process of the coreless rod, the die moves radially to forge the blank of the rotary forging shaft, and the variable cross section and the variable wall thickness of the blank are determined by the die structure; the blank also needs to be fed in the circumferential direction after the radial feeding, and the rotary swaging of the coreless rod is alternately carried out between the radial feeding and the circumferential feeding. After the structures and the sizes of the die and the blank are determined, the rotary swaging deformation and the maximum deformation position of the blank can be determined by rotary swaging radial feeding, the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod are determined by an elastoplastic finite element simulation method, and the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod are determined by simulation under the condition that the rotary swaging radial feeding amount of the coreless rod is certain;
given the structure and dimensions of the die, the structure and dimensions of the original blank, and the material properties of the blank for this example, by elastoplastic finite element simulation, a typical radial feed of a coreless rod is given as 0.3mm, the minimum B and maximum a swages of the inner and outer swages of the coreless rod are shown in fig. 2 (a), (B), and for process convenience, the inner and outer circular deformations in fig. 2 are a result of a 10-fold magnification.
Due to the symmetry of the die and the blank, the rotary swaging deformation of the inner circle and the outer circle of the rotary swaging without the mandrel also presents symmetry, and the symmetry axes are straight lines of 0 degree, 45 degrees, 90 degrees and 135 degrees. The maximum deformation position of the inner circle and the outer circle of the coreless bar swaging is at 45 degrees, 135 degrees, 225 degrees and 315 degrees, and the minimum deformation position is at 0 degrees, 90 degrees, 180 degrees and 270 degrees.
2. Determining the relationship between the maximum deformation amount of the inner circle and the outer circle of the mandrel-free rotary forging and the radial feed amount
The relationship between the maximum deformation amount of the inner circle and the outer circle of the mandrel-free rotary swaging and the radial feeding amount can be solved through theory and simulation, and due to the complexity of the mandrel-free rotary swaging, the theoretical solution is very difficult or even impossible. The invention provides a method for simulating the maximum deformation of the inner circle and the outer circle of the mandrel-free rotary swaging by giving different radial feeds through an elastic-plastic finite element simulation method, so as to establish the relationship of the change curve between the maximum deformation of the inner circle and the outer circle of the mandrel-free rotary swaging and the radial feed.
For this example, given the configuration and dimensions of the die, the configuration and dimensions of the blank, and the material properties, by elastoplastic finite element simulation, given the radial feeds of the coreless rod of 0.2, 0.3mm, 0.5mm, 0.6, 0.7mm, respectively, the established curve relationships for the maximum deformation of the inner and outer circles for different radial feeds of the rotary swaging of the coreless rod are shown in fig. 3 (a), (b). For the present example, the maximum deformation of the inner and outer circles under any radial feed can be solved by using a mathematical interpolation or extrapolation method through the curve relationship of the maximum deformation of the corresponding inner and outer circles under different radial feeds of the coreless rod rotary swaging.
3. Determining critical geometry of swaging quality from geometric deformation of mandrel-free swaging
After the structure and the size of the mandrel-free rotary forging die, the structure and the size of the blank and the mechanical properties of the material are determined, the mandrel-free rotary forging deformation shape is related to the radial feeding amount. The mandrel-free rotary swaging takes different geometrical deformation shapes at different radial feeding amounts, and the mandrel-free rotary swaging deformation takes three shapes from a circle shape to a convex shape to a critical shape to a concave shape with the gradual increase of the radial feeding amount, as shown in fig. 4 (a), (b) and (c), wherein the deformation amount is enlarged by 10 times for the convenience of observing the rotary swaging deformation. When the rotary swaging deformation is convex, the folding defect can not occur in the subsequent rotary swaging process; when the rotary swaging deformation is concave, folding defects can occur in subsequent rotary swaging, and the quality of rotary swaging products is seriously influenced. The boundary between the convex shape and the concave shape is the critical geometric shape of the coreless rod rotary swaging, which is the critical geometric shape for ensuring the quality of the coreless rod rotary swaging.
4. Determining radial critical geometric feed amount of mandrel-free rotary swaging according to critical geometric shape
According to the critical geometric shapes of the inner circle and the outer circle of the coreless rod, the maximum deformation amount under the critical geometric shapes of the inner circle and the outer circle can be obtained by combining the structure and the size of the die, the size of the blank and the material characteristics of the blank; and finally, the geometric critical radial feed amount of the rotary swaging of the coreless rod can be obtained by utilizing the relationship between the maximum deformation amount of the inner circle and the outer circle of the rotary swaging of the coreless rod and the radial feed amount. Due to the complexity of the mandrel-free rotary swaging, the theoretical calculation of the maximum deformation under the critical geometry of the inner circle and the outer circle is very difficult or even impossible. The invention provides a method for simulating by using elastic-plastic finite elements, which simulates and obtains the corresponding relation between the maximum rotary swaging deformation and the geometric critical radial feed of the rotary swaging of the coreless rod when the inner circle and the outer circle of the rotary swaging of the coreless rod are in the critical geometric shapes of the rotary swaging by researching and calculating the deformation shape and the deformation characteristics of the rotary swaging of the coreless rod.
For this example, it can be determined by the elasto-plastic finite element method that when the radial feed of the original blank is 0.55mm, the swaging deformation substantially assumes the critical geometry, in which case the maximum deformation is about 0.33mm and the critical radial feed of the mandrel-less swaging geometry is 0.55 mm.
5. Calculation process of radial critical geometric feed amount in coreless rod rotary forging process
The rotary swaging process of the coreless rod is a process that the inner diameter and the outer diameter of a blank are continuously reduced and the wall thickness is continuously increased, along with the proceeding of the rotary swaging process of the coreless rod, the outer diameter of the blank is continuously reduced, the contact area of the blank and a die can be continuously changed, the rotary swaging deformation shape and the maximum deformation position can be changed along with the reduction of the outer diameter of the blank, and the radial critical geometric feeding amount of the rotary swaging of the coreless rod can also be changed along with the reduction of the outer diameter of the blank. Therefore, the radial feeding amount of each-pass mandrel-free rotary swaging needs to be recalculated and determined, the rotary swaging deformation shape and the maximum deformation amount need to be recalculated, the critical geometric shape and the critical deformation amount are determined, and finally the radial critical geometric feeding amount of the subsequent-pass mandrel-free rotary swaging is determined according to the relationship between the rotary swaging deformation amount and the rotary swaging radial feeding amount. The flow of calculation of the radial critical geometric feed for the coreless bar swaging process is shown in figure 5.
Claims (5)
1. A method for determining radial critical geometric feed amount of a coreless rod rotary swaging is characterized by comprising the following steps:
(1) determining the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod
In the rotary forging process of the coreless rod, the die moves radially to forge the blank of the rotary forging shaft, and the variable cross section and the variable wall thickness of the blank are determined by the die structure; the blank also needs to be fed in the circumferential direction after the radial feeding, and the rotary swaging of the coreless rod is alternately carried out between the radial feeding and the circumferential feeding; after the structures and the sizes of the die and the blank are determined, the rotary swaging deformation and the maximum deformation position of the blank can be determined by rotary swaging radial feeding, the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod are determined by an elastoplastic finite element simulation method, and the rotary swaging deformation and the maximum deformation position of the inner circle and the outer circle of the rotary swaging of the coreless rod are determined by simulation under the condition that the rotary swaging radial feeding amount of the coreless rod is certain;
(2) determining the relationship between the maximum deformation amount of the inner circle and the outer circle of the mandrel-free rotary forging and the radial feed amount
The maximum deformation of the inner and outer circles of the mandrel-free rotary forging is simulated by setting different radial feeds through an elastic-plastic finite element simulation method, and then the change curve relation between the maximum deformation of the inner and outer circles of the mandrel-free rotary forging and the radial feed is established;
(3) determining a critical geometric shape satisfying the quality of swaging based on the geometric deformation of mandrel-free swaging
The mandrel-free rotary swaging presents different geometric deformation shapes when different radial feeding amounts are adopted, the mandrel-free rotary swaging presents three shapes from circle to convex to critical to concave along with the gradual increase of the radial feeding amount, and the boundary shape of the convex deformation and the concave deformation is the critical geometric shape of the mandrel-free rotary swaging, which is the critical geometric shape for ensuring and meeting the mandrel-free rotary swaging quality;
(4) determining radial critical geometric feed amount of mandrel-free rotary swaging according to critical geometric shape
By applying an elastic-plastic finite element simulation method, by researching and calculating the deformation shape and the deformation characteristics of the mandrel-free rotary swaging, the corresponding relation between the maximum rotary swaging deformation and the critical radial feed of the mandrel-free rotary swaging geometry when the inner and outer circles of the mandrel-free rotary swaging are in the critical rotary swaging geometry is obtained through simulation;
(5) calculation process of radial critical geometric feed amount in coreless rod rotary forging process
The rotary swaging process of the coreless rod is a process that the inner diameter and the outer diameter of a blank are continuously reduced and the wall thickness is continuously increased, along with the rotary swaging process of the coreless rod, the outer diameter of the blank is continuously reduced, the contact area of the blank and a die is continuously changed, the rotary swaging deformation shape and the maximum deformation position are changed along with the reduction of the outer diameter of the blank, and the radial critical geometric feeding amount of the rotary swaging of the coreless rod is also changed along with the reduction of the outer diameter of the blank; therefore, the radial feeding amount of each-pass mandrel-free rotary swaging needs to be recalculated and determined, the rotary swaging deformation shape and the maximum deformation amount need to be recalculated, the critical geometric shape and the critical deformation amount are determined, and finally the radial critical geometric feeding amount of the subsequent-pass mandrel-free rotary swaging is determined according to the relationship between the rotary swaging deformation amount and the rotary swaging radial feeding amount.
2. The coreless rod swaging radial critical geometry feed amount determination method of claim 1, wherein: the blank of the rotary swaging shaft is a seamless steel pipe with equal cross section and equal wall thickness, the outer diameter is 37mm, the wall thickness is 5mm, the length is 357mm, and the material characteristics of the blank are that the yield strength is less than 400MPa, the tensile strength is less than 630MPa, and the surface hardness is less than 190 HV.
3. The coreless rod swaging radial critical geometry feed amount determination method of claim 1, wherein: in the step 1, the radial feed amount of a typical coreless rod is given to be 0.3mm through elastic-plastic finite element simulation, the adopted die and the blank have symmetry, the rotary swaging deformation of the inner circle and the outer circle of the coreless rod rotary swaging also presents symmetry, and the symmetry axes are straight lines of 0 degree, 45 degrees, 90 degrees and 135 degrees; the maximum deformation position of the inner and outer circles of the coreless bar swage is at 45 °, 135 °, 225 °, 315 ° and the minimum deformation position occurs at 0 °, 90 °, 180 °, 270 °.
4. The coreless rod swaging radial critical geometry feed amount determination method of claim 1, wherein: in the step 2, when the radial feeding amounts of the mandrel-free rod are respectively 0.2 mm, 0.3mm, 0.5mm, 0.6 mm and 0.7mm through elastic-plastic finite element simulation, a curve relation of the maximum deformation amounts of the corresponding inner circle and the outer circle under different radial feeding of the mandrel-free rotary swaging is established, and then the maximum deformation amounts of the inner circle and the outer circle under any radial feeding can be solved by utilizing a mathematical interpolation and extrapolation method.
5. The coreless rod swaging radial critical geometry feed amount determination method of claim 1, wherein: in step 4, by using an elastic-plastic finite element method, when the radial feed amount of the blank of the rotary swaging shaft is 0.55mm, the rotary swaging deformation basically presents a critical geometric shape, at the moment, the maximum deformation amount is about 0.33mm, and the geometric critical radial feed amount of the rotary swaging without the mandrel is 0.55 mm.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7197906B2 (en) * | 2005-06-28 | 2007-04-03 | Sumitomo Metal Industries, Ltd. | Cold rolling process for metal tubes |
| CN105772621A (en) * | 2016-01-18 | 2016-07-20 | 上海理工大学 | Determination method for coreless rod rotary forging radial feeding process parameters of car universal transmission shaft |
| CN106734839A (en) * | 2017-01-04 | 2017-05-31 | 上海理工大学 | There is the method for defect in a kind of prevention variable-section variable wall thickness jackshaft rotary swaging process |
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Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7197906B2 (en) * | 2005-06-28 | 2007-04-03 | Sumitomo Metal Industries, Ltd. | Cold rolling process for metal tubes |
| CN105772621A (en) * | 2016-01-18 | 2016-07-20 | 上海理工大学 | Determination method for coreless rod rotary forging radial feeding process parameters of car universal transmission shaft |
| CN106734839A (en) * | 2017-01-04 | 2017-05-31 | 上海理工大学 | There is the method for defect in a kind of prevention variable-section variable wall thickness jackshaft rotary swaging process |
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