Methodology on Precision Cross Wedge Rolling of Camshaft

Traditional cross wedge rolling has been widely used for the production of various kinds of shafts with circular cross sections. However it is normally considered that the shafts with non-circular cross section, such as camshafts and eccentric shafts, cannot be produced using the process. A new and innovative method for forming camshafts that includes non-circular sections by cross wedge rolling is presented in the paper. The procedure and technique of the process for production of camshafts are detailed, which include the detailed tool design methods for the precision process. This design method of roller surface profiles for forming camshafts is developed based on the analysis of relative motion between the roller and the camshaft, and a mathematical model of the tool surface has been set up. The model for the precision process of the camshaft has been carried out using the commercial FEM software DEFORM-3D. The process of forming a camshaft via cross wedge rolling is simulated. Tests have been carried out for forming the camshaft by the new developed process. The test results confirmed the new method. The newly developed process can be readily used in the automotive industry for large scale production of camshafts.