Analysis of Metal Flow Behavior and Residual Stress Formation of Complex Functional Profiles under High‐Speed Cold Roll‐Beating

To obtain a good surface layer performance of the complex functional profile during the high‐speed cold roll‐beating forming process, this paper analyzed the metal plastic flow and residual stress‐formed mechanism by using a theoretical model of the metal flow and residual stress generation. By using simulation software, the cold roll‐beating forming process of a spline shaft was simulated and analyzed. The metal flow and residual stress formation law in the motion were researched. In a practical experiment, the changes in the grains in the spline tooth profile section and the residual stress distribution on the tooth profile were studied. A microcorrespondence relationship was established between the metal plastic flow and the residual stress generation. The conclusions indicate that the rate at which the metal flow decreases changes gradually at different metal layers. The residual stress value is directly related to the plastic flow difference. As the roll‐beating speed increases, the uneven degree of plastic deformation at the workpiece surface increases, and the residual stress in the tooth profile is generally greater. At the same roll‐beating speed, the rate change trend of the metal flow decreases gradually from the surface to the inner layer and from the dedendum to the addendum. The residual stress distribution on the surface of the tooth profile decreases from the dedendum to the addendum. These findings provide a basis and guidance for the controlled use of residual stress, obtaining better surface layer quality in the high‐speed cold roll‐beating process of the complex functional profile.