Numerical Simulation on Flat-corrugated Cross Wedge Rolling of 42CrMo4/45 Steel Hollow Laminated Shaft

LEI Haitao; LI Zixuan; SHU Xuedao; PATER Zbigniew

doi:10.3969/j.issn.1674-6457.2025.07.003

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (7) : 21-30. DOI: 10.3969/j.issn.1674-6457.2025.07.003

Composite Material Rolling Technology and Equipment

Numerical Simulation on Flat-corrugated Cross Wedge Rolling of 42CrMo4/45 Steel Hollow Laminated Shaft

LEI Haitao¹, LI Zixuan^1,*, SHU Xuedao¹, PATER Zbigniew²

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Abstract

The work aims to enhance the interfacial bonding strength of dissimilar metal hollow laminated shafts and achieve high-strength, lightweight, and low-cost shaft components for new energy vehicles and other industrial applications. A flat-corrugated cross wedge rolling process for 42CrMo4/45 steel hollow laminated shafts was proposed. Numerical simulation models were constructed using Simufact.forming software to analyze the effects of different layer thickness ratios (1.7∶1, 1.25∶1, and 1.08∶1) and rolling temperature (1 000, 1 100, 1 200 ℃) on forming quality. By comparing equivalent plastic strain distribution, equivalent stress distribution, and z-axis force between corrugated and traditional cross wedge rolling processes, the effect of corrugated wedges on deformation behavior and interfacial corrugation transfer mechanisms were investigated. The maximum rolling force during the corrugated die rolling stage reached approximately 70 kN, while the master die rolling stage peaked at about 290 kN, representing a 45% increase compared with traditional dies. The symmetrically distributed corrugated wedges progressively penetrated the outer shaft surface, forming regular spiral corrugations on the outer shaft surface and complementary corrugated structures at the inner-outer shaft interface. At a 1.7∶1 layer thickness ratio, the outer shaft exhibited distinct and uniform plastic deformation distribution in the early rolling stage, with optimal coordination between inner and outer shafts, effective corrugation interface transfer, and suppression of ovalization during rolling. At a 1.25∶1 ratio, deformation concentrated in the middle section, showing a “middle bulging” phenomenon. At a 1.08∶1 ratio, by the middle stage of the rolling process, the inner shaft displayed large areas of high equivalent strain values, indicating potential risks of interface separation and flattening. Regarding temperature effects, at 1 100 ℃, the interfacial normal stress distribution was uniform and generally exceeded the yield strength of 45 steel, ensuring good interfacial bonding. In conclusion, the flat-corrugated cross wedge rolling process successfully creates corrugated bonding interfaces in 42CrMo4/45 steel hollow laminated shafts, improving axial shear resistance and circumferential torsional ability. The research results provide a new approach to addressing the insufficient interfacial bonding strength problem in traditionally manufactured laminated shafts.

Key words

laminated shaft / flat cross wedge rolling / corrugation / numerical simulation / interface

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LEI Haitao, LI Zixuan, SHU Xuedao, PATER Zbigniew. Numerical Simulation on Flat-corrugated Cross Wedge Rolling of 42CrMo4/45 Steel Hollow Laminated Shaft[J]. Journal of Netshape Forming Engineering. 2025, 17(7): 21-30 https://doi.org/10.3969/j.issn.1674-6457.2025.07.003

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Funding

; Fund：The National Natural Science Foundation of China (52205403); Zhejiang Provincial Natural Science Foundation (LY24E050002); Ningbo Science and Technology Major Special Project (2023Z011); Ningbo Yongjiang Talent Program (2023A-157-G); China-Central and Eastern European Countries Joint Education Program (2023320); Mechanics Interdisciplinary Fund for Outstanding Young Scholars of Ningbo University (ZX2025000396)