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To enhance the forming accuracy and material utilization rate of hollow shafts with equal-wall-thickness by
three-roll skew rolling (TRSR), the influence of process parameters on the forming quality of these shafts
was investigated through a combination of finite element simulation and experimental validation. Firstly, by
analyzing the characteristics of TRSR, a finite element model for hollow shafts with equal-wall-thickness by
TRSR was established, and the out-of-roundness and wall thickness distribution of the hollow shafts were
defined. Subsequently, finite element simulations were conducted to analyze the impact of key process
parameters, such as rolling temperature and axial feeding velocity, on the out-of-roundness and wall
thickness distribution of the hollow shafts. Finally, experimental validation was performed to confirm the
influence of process parameters on the forming quality of hollow shafts with equal-wall-thickness. The
results indicate that TRSR technology can effectively control the roundness error of the formed parts.
Better roundness and wall thickness uniformity can be achieved at lower rolling temperatures and mod-
erate axial feeding velocities. The findings reveal that optimized process parameters play a crucial role in
improving the forming quality of hollow shafts with equal-wall-thickness. This research holds significant
theoretical and practical implications for the manufacture of lightweight, high-performance hollow shafts in
fields such as aerospace and new energy vehicles.
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