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This research was funded by the National Natural Science Foundation of China (Grant no.
51975301), the Natural Science Foundation of Zhejiang, China (grant number: LZ22E050002) and
the Major Project of Science and Technology Innovation 2025 in Ningbo City, China (grant number:
2022Z009 and 2022Z064).
The hollow axle is the key component of the high-speed train, and the realization of high-
quality forming is the key to ensure the safety of train operation. In this paper, the specimen of the
variable-diameter section of the hollow axle is taken as the research object, and the generation mecha-
nism of surface spiral mark defects and the formula of spiral mark depth of variable-diameter section
in the TRSR (three-roll skew rolling) process with variable roll spacing are explored. The external
roundness error and the function C to measure the wall thickness uniformity of the cross-section were
taken as the evaluation indexes and the single-factor simulation experiment was established and
simulated in the software Simufact.forming16.0 to obtain the influence law of each process parameter
on the external roundness error and wall thickness uniformity of the rolled piece. Orthogonal tests
were designed and the order and optimal combination of process parameters on the forming quality
were obtained by range analysis and ANOVA analysis. The research results provide theoretical
guidance for improving the forming quality of the variable-diameter section of the hollow axle in
three-roll skew rolling, and promote the transformation of the TRSR process to high performance and
accurate forming.
