scholarly journals Research on plastic deformation law and forming technology of rotary forging with multi-cone rolls

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110087
Author(s):  
Qi Wang ◽  
Chun-dong Zhu ◽  
Xin Liu ◽  
Rong-fei Ma
Keyword(s):  
Plastic Deformation ◽  
Large Diameter ◽  
Forming Process ◽  
Element Analysis ◽  
Influence Of Process Parameters ◽  
Rotary Forging ◽  
Forming Technology ◽  
Long Time ◽  
Plastic Forming ◽  
Deformation Area

With the development of industrial technology, the application of large diameter-thickness ratio integral discs in various high precision vessels is becoming more and more important. At present, the forming processes of large-diameter disc mainly includes welding and multiple local upsetting, but these processes exhibit large defects and cannot meet the requirements of industry. Therefore, a new metal plastic forming technology, namely rotary forging with multi-cone rolls (MCRs) is proposed to integrally form large diameter and ultra-thin discs. The forming process was simulated by DEFORM-3D finite element analysis software, and the deformation characteristics of MCRs disc were revealed. The results show that the axial plastic deformation of disc can be divided into three stages. In the first stage, the plastic deformation area was basically symmetrical, and the deformation was relatively stable. In the second stage, the plastic deformation area on both sides was different, which was in the unstable stage and easy to produce defects. In the third stage, the plastic deformation area was approximately symmetrical for a long time, and the plastic deformation was stable. At the same time, the influence of process parameters on the form characteristics of MCRs, the main defects in the deformation process and the preventive measures were studied. The research results are helpful to better understand the metal plastic forming technology of MCRs and promote the further development of MCRs.

scholarly journals Research on forming technology of rotary forging with double symmetry rolls of large diameter : thickness ratio discs

2021 ◽  
Vol 12 (1) ◽  
pp. 625-638
Author(s):  
Rong Fei Ma ◽  
Chun Dong Zhu ◽  
Yu Fan Gao ◽  
Zi Hao Wei
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Large Diameter ◽  
Thickness Ratio ◽  
Forming Process ◽  
Rigid Plastic ◽  
Local Pressure ◽  
Rotary Forging ◽  
Forming Technology ◽  
Double Symmetry

Abstract. Rotary forging with double symmetry rolls (DSRs) is a new metal plastic forming technology developed on the basis of conventional rotary forging with a single roll, which uses a pair of symmetrical cone rolls to realize continuous local pressure plastic deformation of the workpiece. Large-diameter, thin discs are a key component in nuclear power, aerospace, deep-sea exploration, and other fields. At present, the forming process of large-diameter discs mainly includes welding and multiple local upsetting, but these processes exhibit many defects and can not meet the requirements of industry. In this paper, a large diameter : thickness ratio disc is integrally formed by rotary forging with DSRs. Using theoretical calculation and finite element simulation methods, the stable rolling conditions and calculation formulas of force and power parameters of rotary forging with DSRs of a large diameter : thickness ratio disc are derived. Based on the reliable three-dimensional rigid-plastic finite element model, the plastic deformation characteristics of rotary forging with DSRs of discs are studied, the reliability of the stable rolling conditions and the calculation formulas of force and power parameters are verified, and the defects and causes of unstable rolling conditions are analysed. An experiment was carried out on a rotary forging press developed with double symmetry rolls, and the experimental results are in good agreement with simulation results, which demonstrated that rotary forging with DSRs is a reliable technology for forming large diameter : thickness ratio discs. The results of this research are helpful to promote the further development of rotary forging with DSRs.

Coupled Thermo-Mechanical FEA of Three-Roll Cross Rolling Process for Rings with Small-Hole and Deep Groove

2012 ◽  
Vol 560-561 ◽  
pp. 846-852 ◽  
Author(s):  
Qi Ma ◽  
Lin Hua ◽  
Dong Sheng Qian
Keyword(s):  
Rolling Process ◽  
Small Hole ◽  
Fe Model ◽  
Forming Process ◽  
Software Environment ◽  
Cross Rolling ◽  
Design And Optimization ◽  
Forming Technology ◽  
Deep Groove ◽  
Plastic Forming

Ring parts with small-hole and deep groove such as duplicate gear and double-side flange, are widely used in various engineering machineries. Three-roll cross rolling (TRCR) is a new advanced plastic forming technology for the processing of rings with small-hole and deep groove. In this paper, a 3D coupled thermo-mechanical FE model for TRCR of ring with small-hole and deep groove is established under ABAQUS software environment. By simulation and analysis, the evolution and distribution laws of strain and temperature in the forming process are revealed, and the effects of the key process parameters on the deformation uniformity are explored. The results provide valuable guideline for the technological parameter design and optimization.

Process Optimization for Suction Plastic Forming of In-Mold Decoration Plastic Sheet with CAE

2010 ◽  
Vol 102-104 ◽  
pp. 74-78
Author(s):  
Bin Gao ◽  
Xiu Rong Nan ◽  
Bai Zhong Wu
Keyword(s):  
Process Optimization ◽  
Thin Shell ◽  
Optimization Methods ◽  
Analysis Software ◽  
Optimization Scheme ◽  
Forming Process ◽  
Element Analysis ◽  
Plastic Sheet ◽  
Mesh Model ◽  
Plastic Forming

The suction plastic forming process for in-mold decoration plastic sheet has been the best process for thin-shell plastic exterior decoration parts. But the suction plastic forming products still suffers from the uneven thickness. Based on the general finite element analysis software POLYFLOW for viscoelastic fluid, a set of optimization methods for suction plastic forming process of in-mold decoration plastic sheet is introduced in this paper to reduce the uneven level of thickness. These methods include establishing process optimization scheme, building mesh model, selecting the material constitutive model and determining its parameters, imposing boundary conditions and blowing pressure, and applying the mold movement. Finally, the optimized suction plastic forming process is used to produce the in-mold decoration plastic rear bumper sample of an automobile, and the results show that optimized process is effective and applicable.

Numerical Simulation of Non-Circular Hole Joint Precision Forming

2009 ◽  
Vol 16-19 ◽  
pp. 462-465
Author(s):  
Yong Fei Gu ◽  
Jun Ting Luo
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Circular Hole ◽  
Developed Countries ◽  
Forming Process ◽  
Backward Extrusion ◽  
Forming Technology ◽  
Plastic Forming ◽  
And Performance

The precision forming technology developed rapidly during passing two decades, however technologies of precision plastic forming the parts with deeper hole are far behind developed countries. The warm backward extrusion-ironing forming technology was presented for precision forming of non-circular hole joint in this paper. The forming process and parameter variable trend were simulated by finite element method, which the software MSC.Marc was applied. The forming die was designed and the forming experiment was finished. The products were deserved with good quality and performance. The feasibility of the forming technology is proved by experimental results and numerical simulation.

Researches on Control and Application of Wrinkles in the Thin-Walled Metal Plastic Forming Process

2013 ◽  
Vol 446-447 ◽  
pp. 1193-1196
Author(s):  
Zhu Lin Hu ◽  
Lian Fa Yang ◽  
Yu Lin He
Keyword(s):  
Metal Forming ◽  
Thin Metal ◽  
Forming Process ◽  
Forming Technology ◽  
Plastic Forming ◽  
The Common ◽  
Thin Walled

The thin metal plastic forming is an indispensable metal forming technology. Wrinkling is one of the common defects in plastic forming. If this kind of defects can be used properly, the formability of metal will be better. In this paper, the recent researches on the methods of identifying wrinkles, distinction of the useful wrinkles and harmful wrinkles, control and application of the wrinkles are summarized. The useful wrinkles are expected to improve the forming property.

scholarly journals Forming Characteristics and Mechanism of Double-roll Rotary forging for Large Diameter and Thin-walled Metal Discs

2021 ◽  
Author(s):  
Zhongquan Yu ◽  
Chundong Zhu ◽  
Mingchao Chen ◽  
Site Luo
Keyword(s):  
High Surface ◽  
Large Diameter ◽  
Equivalent Stress ◽  
Low Noise ◽  
Forming Process ◽  
Eccentric Load ◽  
Geometric Shapes ◽  
Rotary Forging ◽  
Forming Characteristics ◽  
Thin Walled

Abstract Double-roll rotary forging is an emerging plastic forming technology based on rotary forging. Owing to the advantages of labor saving, small eccentric load, low noise and vibration, good uniformity, high surface quality and material saving, it is very promising for fabrication of large-diameter thin-walled disc. To date, few relevant research on the double-roll rotary forging technology of large-diameter thin-walled metal discs has been reported, and the forming mechanisms and process of disc workpieces remains uninvestigated. Herein, a 3D rigid-plastic finite element model (FEM) is established to simulate the fabrication process of large-diameter thin-walled disc, four geometric features appear in the forming process: “mushroom” shape, “upper drum” shape, “drum shape” shape and “lower drum” shape. Equivalent stress, equivalent strain and temperature field of these four geometric shapes are analyzed, and the forming mechanism of these four geometric shapes is revealed. The reliability and accuracy of FEM are verified through experiments and the four geometric shape features occur in the process are consistent with the simulation. The research results provide valuable guidelines for better understanding of double-roll rotary forging for the fabrication of large-diameter thin-walled discs.

Synchronized Hydraulic Bulging Forming Technology of Three-Layer-Metal Tubes

2010 ◽  
Vol 143-144 ◽  
pp. 1059-1064
Author(s):  
Wei Wei Wang ◽  
Jian Li Song ◽  
Jing Bo Yu ◽  
B.B. Jia
Keyword(s):  
Numerical Simulation ◽  
Finite Element Analysis ◽  
Theoretical Analysis ◽  
Main Process ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Technology ◽  
Comparison Of The Results ◽  
Hydraulic Bulging ◽  
The Relationship

Synchronized hydraulic bulging forming technology on three-layer-metal tubes was studied. The possibility of three-layer-metal tubes formed by hydraulic bulging method was discussed and proved by elastic-plastic theory. The calculation formulas about the bulging pressure, the residual contact stress and the relationship between them were derived and the main process parameters were analyzed. Finite element analysis was carried out on bulging forming process using MSC. Marc. Practical bulging forming experiments were conducted and well compounded three-layer-metal tubes with tight interfaces were obtained. Through the comparison of the results of theoretical analysis, numerical simulation and practical experiments, proper parameters for the bulging process were obtained and the theoretical analysis was verified and proved.

3D FE Modeling Simulation of Cold Rotary Forging with Double Symmetry Rolls

2009 ◽  
Vol 628-629 ◽  
pp. 623-628
Author(s):  
Xing Hui Han ◽  
Lin Hua ◽  
Yumin Zhao
Keyword(s):  
Innovative Technology ◽  
Fe Model ◽  
Software Environment ◽  
Rotary Forging ◽  
Modeling Simulation ◽  
Forming Technology ◽  
Plastic Forming ◽  
As Stress ◽  
Cold Rotary Forging ◽  
Double Symmetry

A novel metal plastic forming technology, cold rotary forging with double symmetry rolls, is presented on the basis of cold rotary forging with single roll. A reasonable 3D elastic-plastic dynamic explicit FE model of cold rotary forging with double symmetry rolls is developed under the ABAQUS software environment. Through simulation, the distributions and histories of different field-variables such as stress, strain and force and power parameters are investigated in detail. The research results not only provide an advanced and innovative technology for metal plastic forming, but also help to better understand cold rotary forging with double symmetry rolls.

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