Investigation of cavity filling in profile ring rolling process for T-shape ring

2021 ◽  
pp. 146442072110075
Author(s):  
Hosein Zayadi ◽  
Ali Parvizi ◽  
Hamid Reza Farahmand ◽  
Davood Rahmatabadi
Keyword(s):  
Rotational Velocity ◽  
Element Model ◽  
Rolling Process ◽  
Ring Rolling ◽  
Feed Speed ◽  
Filling Rate ◽  
Roll Torque ◽  
Axial Forces ◽  
Cavity Filling ◽  
Ring Rolling Process

In this paper, key parameters affecting the cavity filling in single and double T-shape profile rings are comprehensively investigated via numerical and experimental analysis. A three-dimensional finite element model was developed in Abaqus\Explicit to assess the influence of crucial ring rolling process parameters, including feed speed, main roll rotational velocity, the existence and the absence of axial rolls on the cavity filling of single and T-shape rings and the main roll torque. Besides, a ring rolling machine was built to conduct practical experiments and validate the numerical evaluation, while for the first time, the role of the axial roll and the main roll torque on the quality of the cavity filling is experimentally evaluated. Power requirements and the final ring profile geometry were obtained by the simulation method, and the results were confirmed by the experiments. The results showed that axial rollers significantly reduced the cavity filling rate, and in contrast, the effect of mandrel feed speed and the main roll rotational velocity was much lower. Also, the axial forces were considerably less than the radial forces. However, the rolling operation was done in both radial and axial directions. The existence of axial rolls had an intensive effect on the process’ required power, as a result the main roll torque increased more than three times in case of applying axial rolls, compared with not considering them. Severe effects of axial rollers on increasing force and decreasing cavity filling rate can be attributed to frictional forces between the ring and axial rolls, restricted ring motion, which has to be compensated by a higher torque of the main roll. When the axial rolls are used, the material flow in the ring’s height direction is restricted. Therefore, the material cannot move easily to form the profile. All experimental and simulation results, including mandrel force, cavity filling, and ring profile geometry, were in good agreement, and in all cases, the simulation error was less than 10%.

Investigation on Constant and Variable Feed Speeds Effects in Ring Rolling Process Using 3D FEM

2011 ◽  
Vol 264-265 ◽  
pp. 1776-1781 ◽  
Author(s):  
Nassir Anjami ◽  
Ali Basti
Keyword(s):  
Finite Element ◽  
Rolling Process ◽  
Ring Rolling ◽  
Outer Diameter ◽  
Fe Model ◽  
Feed Speed ◽  
3D Fem ◽  
Cold Ring Rolling ◽  
Plastic Deformation Behavior ◽  
Ring Rolling Process

Although cold ring rolling (CRR) process is largely used in the manufacturing of profiled rings like bearing races, research on this purpose has been scant. In this study, based on a validated finite element (FE) model, CRR process is simulated regarding the variable and constant feed speeds of the mandrel roll which lead to constant and variable values of the ring's diameter growth rates respectively using a 3D rigid-plastic finite element method (FEM). Major technological problems involved in the process including plastic deformation behavior, strain distribution and its uniformity, Cockcroft and Latham damage field and final outer diameter of ring are fully investigated. The results of simulations would provide a good basis for process control especially feed speed controlled mills and guiding the design and optimization of both cold and hot ring rolling process.

An Analytical Approach to Ring Rolling Using Modified Slab Analysis

2011 ◽  
Vol 383-390 ◽  
pp. 4634-4641
Author(s):  
Ali Parvizi ◽  
Karen Abrinia ◽  
Mohsen Hamedi
Keyword(s):  
Friction Factor ◽  
Rolling Process ◽  
Ring Rolling ◽  
Shear Stresses ◽  
Feed Speed ◽  
Shear Yield ◽  
Experimental Works ◽  
Ring Rolling Process ◽  
Good Agreement ◽  
Normal And Shear Stresses

In this paper, based on the modified slab method theory, an analytical solution for ring rolling process is presented. The non-uniformity of the normal and shear stresses across the section of the deforming material are considered. The friction factor multiplied by the shear yield strength is used to present friction between the main roll and the ring. Complete expressions for the ring rolling pressure, force and torque are obtained and the position of neutral point is predicted. The influence of the process parameters such as friction factor, main roll rotational speed, feed speed, and others was investigated. Analytical results obtained from the present formulation were compared to previous experimental works and good agreement and improvements were observed.

Research on Edge Cracks of the Ring Part During Ring Rolling Based on Cast Blank

2015 ◽  
Author(s):  
Huiping Qi ◽  
Yongtang Li ◽  
Xiaojian Wei ◽  
Li Ju ◽  
Dongsheng Qian
Keyword(s):  
Rolling Process ◽  
Ring Rolling ◽  
Feed Speed ◽  
Forming Process ◽  
The Core ◽  
Initial Stage ◽  
Initiation And Propagation ◽  
New Process ◽  
Edge Cracks ◽  
Ring Rolling Process

The casting-rolling compound forming process is a new process to produce seamless ring shaped components. In the new process, the input blank for the new process is a ring shaped casting blank. Edge crack affects severely the quality of rolled ring parts in ring rolling process based on cast blank. Theoretical analysis, numerical simulation and experiments were combined to study the edge crack and its prevention methods during ring rolling. Conclusions are obtained that: (1) for casting blank, the initial stage of ring rolling is crucial to prevent the initiation and propagation of the edge cracks. (2) in the ring rolling process, the occurrence of cracks were influenced mainly by rolling temperature and feed speed of the core-roller. Cracks could be avoided by controlling above two rolling parameters. (3) in the initial stage of ring rolling, higher rolling temperature and lower feed speed of the core-roller are beneficial to improve the plasticity of the materials and restrain effectively the initiation and propagation of cracks. The work is a part of the research of the new casting-rolling compound forming process. It will promote the development of the new process.

Feed Speed Design and Optimization in Radial-Axial Ring Rolling Process by FEM

2011 ◽  
Vol 421 ◽  
pp. 513-521
Author(s):  
Shi Biao Liu ◽  
Ke Lu Wang ◽  
Shi Qiang Lu ◽  
Xin Li ◽  
Xian Juan Dong
Keyword(s):  
Rolling Force ◽  
Effective Strain ◽  
Rolling Process ◽  
Ring Rolling ◽  
Fe Model ◽  
Feed Speed ◽  
Rigid Plastic ◽  
Axial Ring ◽  
Ring Rolling Process

Radial-axial ring rolling is an important component of advanced manufacturing technology, but it has characteristics of high nonlinear on geometry and physics, so the radial-axial ring rolling process becomes very complex. In addition, the feeding mode of core roller has enormous influence on the quality of the rolled ring as well as the stability of the process. In this paper, a 3D rigid-plastic FE model of radial-axial ring rolling process is established, then three kinds of feed speed design ((1)constant of feed speed; (2)constant of feed in one rotary; (3)variation of feed speed)are offered. The difference of outer radius growth velocity, distribution of effective strain and temperature, rolling force, size of ring are analysised for the three kinds of feed methods. And, an optimized feed method is proposed base on analytic results, the optimized feed method can improve the quality of formed ring, and decrease the requirement of ring rolling mill.

Key Technologies for 3D-FE Modeling of Radial-Axial Ring Rolling Process

2008 ◽  
Vol 575-578 ◽  
pp. 367-372 ◽  
Author(s):  
L.G. Guo ◽  
He Yang
Keyword(s):  
Modeling And Simulation ◽  
Optimum Design ◽  
Rolling Process ◽  
Ring Rolling ◽  
Fe Modeling ◽  
Precise Control ◽  
Key Technologies ◽  
Axial Ring ◽  
Forming Characteristics ◽  
Ring Rolling Process

Nowadays, 3D-FE Modeling and simulation is an indispensable method for the optimum design and precise control of radial-axial ring rolling process for its complexities. In this paper, the unique forming characteristics of radial-axial ring rolling have first been summarized, and then some key technologies for 3D-FE modeling of the process have been presented and their solution schemes have been given out, lastly the modeling and simulation of radial-axial ring rolling process have been realized using elastic-plastic dynamic explicit procedure under ABAQUS environment. The work provides an important basis and platform for the future investigations, such as forming mechanism and laws, process optimum design and precise control.

Effect of the Guide-Roll Positional Angle to the Stability of Radial Ring Rolling

2007 ◽  
Vol 561-565 ◽  
pp. 1875-1878 ◽  
Author(s):  
Yong Xing Hao ◽  
Lin Hua ◽  
Gui Shan Chen ◽  
Dao Ming Wang
Keyword(s):  
Position Angle ◽  
Rolling Process ◽  
Ring Rolling ◽  
Positional Angle ◽  
The Mean ◽  
The Stability ◽  
Ring Rolling Mill ◽  
Ring Rolling Process ◽  
Ring Blank ◽  
Evaluating Method

Non-stability factors affect stability of radial ring rolling process, and lead to fluctuating of ring position. This decreases rolling precision. Evaluating stability of the process is very important. A stability evaluating method is proposed. The stability can be measured with the mean square root of sequence of oscillation of ring geometrical centerline displacement. Using ABAQUS/Explicit, the stability is analyzed. It is showed that guide-roll position angle has the significant effect to the stability. If guide-roll is located at the tangential position to the ring’s fringe, the stability will vary with the angle between two planes. One passes through axes of guide roll and ring blank, and another passes through axes of drive roll and ring blank. The stability is highest when guide roll is situated at the position angle of 100˚to 130˚at exit side of ring rolling mill.

Sign in / Sign up

Export Citation Format

Share Document