Numerical simulation of superplastic roll-forming of a hollow shaft out of nickel-based superalloy

Numerical simulations of superplastic roll-forming used for manufacturing of hollow shafts out of superalloys are carried out. Configurations of the workpiece and roller, mutual orientations of their rotation planes are varied. Various initial cone-shaped blanks with angles of 15° to 45° between the generatrix and axis, and initial positions of the roller are considered. As a result, an optimal design of the workpiece and tool, which allows one to obtain required shapes and dimensions of a shaft with a bearable deformation load on the existing roll forming equipment are determined. Basing on this, an optimal shape of a blank with a cone angle of 30° is selected.