The metallographic structures of the two types of rolling wheel bodies differ significantly, which suggests that the materials have been used under different conditions. These differences are primarily due to variations in heat treatment processes. The way cracks propagate is largely influenced by the metallurgical quality of the steel and its mechanical properties during operation.
Different tooth designs affect the material's resistance to deformation during processing. For parts requiring higher hardness, it is necessary to increase the rolling wheel’s hardness accordingly. This variation leads to differences in working stress, with flat-bottomed rolling wheels experiencing higher stress compared to their round-bottomed counterparts, contributing to their distinct performance characteristics.
Therefore, the existing steel should be either strengthened or toughened, or a high-strength rolling wheel made from a more ductile steel than CrlZMoV should be used to improve its performance under operational conditions.
The thread-forming method on the rolling wheel has a significant impact on its overall performance. Rolling threads can enhance precision and improve the strength of the teeth by aligning the material flow lines. However, if not carefully controlled, this process may retain defects from previous steps, such as unremoved surface layers or decarburized areas, which can lead to new flaws.
In contrast, grinding threads offers opposite advantages and disadvantages. While it may provide a smoother finish, it often results in lower efficiency and higher costs. From a cost perspective, rolling threads is generally more favorable.
Through detailed analysis and discussion, we have reached the following conclusions: (1) The structural design of the two rolling wheels differs, and the dome-shaped, round-bottom structure of RDI is a more suitable option. (2) Although the materials used in both types of rolling wheels are similar, their metallurgical quality varies greatly, indicating different service conditions caused by differing heat treatment methods. The crack propagation behavior is mainly influenced by the steel's metallurgical quality. RDZ should implement appropriate strengthening and toughening measures or use steel with better toughness to improve its mechanical performance. (3) The heat treatment processes for the two types of rolling wheels vary, and for high-hardness components, the rolling wheel's hardness must be increased appropriately. At this stage, factors like vibration and noise are receiving increasing attention.
Based on the study of the vibration and noise mechanisms in drive axles, a new approach to noise control in drive axle assemblies has been proposed. It is hoped that this will assist manufacturers in producing quieter drive axle systems.
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