Main Sector of relevance\IRC classification 8. Industrial Manufacturing, Material and Transport Technologies

8.22 Plastic shaping combined technology based on transverse wedge-type rolling and stamping procedures

Developers’ contact information

State Scientific Institution “The Physical-Engineering Institute of the National Academy of Sciences of Belarus”, Metal Science Department, Laboratory for Microcrystalline and Amorphous Materials
10 Academician V.F.Kuprevich Street, Minsk BY-220141

Summary

Combining technologies of transverse wedge-type rolling and stamping provides an opportunity for development of almost non-waste processes with metal recovery making up 0.98. Transverse wedge-type rolling is used for intermediate profile stocks production and further close tolerance forging or any other plastic shaping processes.

Description

The purpose of the development is to ensure maximum material and energy resources saving and high-quality output for die-forging production. The combination of the transverse wedge-type rolling and stamping technologies gives a practically non waste process. Transverse wedge-type rolling is used for intermediate profile stocks production and further close tolerance forging or any other plastic shaping processes. The developed process of screw spikes production can serve an example of its successful application. The technology includes zone heating of 24 mm stocks and screw head mechanical pressing, and then a second cycle of zone heating is carried out followed by 24mm thread transverse wedge-type rolling. The resulting products correspond to GOST 809-71 requirements.
A range of technologies have been developed to ensure resource saving part production, including pre-shaped stock transverse wedge-type rolling and its further close-die stamping in the same heating cycle. For instance, nut wrench manufacturing technology consists of two stages: automatic pre-shaped stock manufacturing from bar stock by means of transverse wedge-type rolling and hammer or press stamping.

“BELKARD”, OJSC (Grodno propeller-shaft plant) (Belarus) has introduced in its production process the newly developed transverse wedge-type rolling to manufacture profile stocks for further stamping of propeller-shaft yokes. Over the period from December, 2006 till November, 2007 “BELKARD”, OJSC stamped 46 675 forgings. The total sum of saving for the period amounted to 56000 USD.

1

2

Propeller-shaft yoke forging

Technology type

• Process

Technical advantages and economic benefits

Competitive advantages:

• 30–60 % reduction in metal consumption rates;
• an increase in working efficiency;
• high-precision and clean product surface;
• 20–30 % improvement in performance characteristics for resulting products;
• tool durability till its complete failure is 1 mln. products;
• elimination and minimization of need for product final mechanical polishing;
• reduction in energy consumption value for the process.

Technology differentiation and uniqueness

Payoff period is less than one year.

Context in which technology was identified

Hannover industrial fair, Moscow International Salon of Innovations and Investments, “Belpromexpo”, “Vietnam EXPO”, International Indian trade fair.

Technological keywords

Plastic deformation, rolling, stamping.

Development Stage

• Currently in use/production

Intellectual property rights

• Patent pending
• Specific Patent Information:
  Patent of Republic of Belarus 3560, IPC В21 H 1/18. Part making processes with the use of bar stock transverse wedge-type rolling and corresponding process equipment of 16.06.1998,
  Patent of Republic of Belarus 298, IPC В21 H 1/18. Rolling mill for bar stock reduction of 03.11.2000,
  Application for a patent of the Republic of Belarus No a20061247, IPC В21 H 1/18. Stepped shaft type products manufacturing by transverse wedge rolling method of 11.12.06,
  Application for a patent of the Republic of Belarus No a20071570, IPC В21 H 1/18. Manufacturing process for stepped shaft type products with the use of transverse wedge rolling method of 18.12.07, etc.

Range of applications

It is applied in manufacturing of parts for motor-vehicle construction, machine-tool building, instrument-making industry, agricultural machine-building, tractor and aircraft, motor and cycle, mining and nuclear power industries. It allows processing of almost every construction steel as well as brass, titanium, zirconium and nickel.

Classifier Used at the EU Innovation Relay Centres

• Industrial Manufacturing, Material and Transport Technologies

Preferable Regions

• North America
• Europe
• Asia
• Australia

Practical experience

State Scientific Institution “Physics and Technology Institute of the Academy of Sciences of Belarus” carries out fundamental research on plasticity and endurance theory, constitutional and structural changes in metals and alloys, impulse and electrophysical metal treatment methods, develops new production and treatment processes for engineering materials and products. Theoretical foundation of the transverse wedge-type rolling method and design of proper tools and equipment is the main activity of the Department for process-oriented deformability. The institute created a school of transverse wedge-type rolling specialists which is recognized as leading all over the world. Innovative cooperation activities engage universities and research institutes in Russia, the USA, China, Poland, Germany, Turkey, Brazil, India, South Korea, Vietnam, Rumania, and the Czech Republic.

Environmental impact

Minimal.

Type of collaboration sought

• Other:
  
  • parts supply,
  • technology transfer,
  • production establishment,
  • transfer of drawings for tools and equipment,
  • specialist training,
  • license sale.

Terms and restrictions

—

Available technical assistance

• Documentation
• Personnel