Investigating the Time-course of Spline Cold Roll Forming Process: A Numerical Simulation Study

The cold forming process of spline is a kind of high speed plastic forming technology. It is generally difficult to observe the whole process through experiment, and the simulated analysis is still insufficient for cold roll forming intensive research. This paper simplified the model of spline cold roll forming, simulated the cold forming process of spline based on Deform 3D software. With the right teeth shape derived from the biting, rough roll forming, fine roll forming and seceding, teeth shape change, cutting tool interface change and the forming stress are analyzed in detail. The forming force is obtained by simulation and its change rule is analyzed. Time-course of spline cold roll forming process simulation and results obtained in this paper can provide references for further research on optimization of cold forming technology and forming machine design.