scholarly journals Numerical Analysis of the Skew Rolling Process for Rail Axles

2015 ◽  
Vol 60 (1) ◽  
pp. 415-418 ◽  
Author(s):  
Z. Pater ◽  
J. Tomczak ◽  
T. Bulzak
Keyword(s):  
Numerical Modeling ◽  
Effective Strain ◽  
Translational Motion ◽  
Rolling Process ◽  
Simulation Software ◽  
Maximum Diameter ◽  
Cross Sectional ◽  
Rolling Method ◽  
Skew Rolling

Abstract The paper describes a new method for producing stepped rail axles. The method is based on the skew rolling process. With this method, the product is formed by three tapered rolls located every 120° on the perimeter of the billet. Positioned askew to the centerline of the billet, the rolls rotate in the same direction and with the same velocity. At the same time, they get closer together or go apart depending on the desired cross sectional reduction of an axle step. In addition, the workpiece is shifted lengthwise relative to the rolls by the translational motion of the workpiece-holding chuck. In order to verify the designed method for producing rail axles, a series of numerical simulations were performed using the Simufact. Forming v.12 simulation software. The numerical modeling enabled the determination of maps of the effective strain and temperature in the finished product as well as variations in the loads and torques during rolling. The numerical results unambiguously confirm that the skew rolling method can be applied to form parts of considerable dimensions (the modeled axles had a length of 2146 mm and their maximum diameter was 202 mm).

scholarly journals Numerical analysis of a skew rolling process for producing a crankshaft preform

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
Konrad Lis ◽  
Łukasz Wójcik ◽  
Zbigniew Pater
Keyword(s):  
Numerical Modeling ◽  
Numerical Analysis ◽  
Cross Section ◽  
Rolling Process ◽  
Damage Function ◽  
New Method ◽  
Rolling Technique ◽  
Rolling Method ◽  
Skew Rolling

Abstract The paper describes a new method for forming a crankshaft preform. The method is based on the skew rolling technique. With this method the part is formed by three tapered rolls rotated with the same velocity and in the same direction. Simultaneously, the rolls either converge or diverge depending on the desired cross section of the product. The numerical modeling enabled determination of the distributions of effective strains, temperatures, and damage function according to the Cockroft - Latham criterion, aswell as variations in the loads and torques during rolling. The results confirm that a crankshaft preform can be formed by the proposed skew rolling method.

scholarly journals A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3084
Author(s):  
Zbigniew Pater
Keyword(s):  
Comparative Analysis ◽  
Effective Strain ◽  
Experimental Tests ◽  
Rolling Process ◽  
Simulation Software ◽  
Compression Technique ◽  
Rolling Mills ◽  
University Of Technology ◽  
Basic Force ◽  
Skew Rolling

The paper presents a comparative analysis of skew rolling in 3- and 4-roll CNC rolling mills. The analysis is performed using the FEM-based commercial simulation software Simufact.Forming. The formation of both solid and hollow railway axles is analyzed. Distributions of effective strain, temperature and damage criterion in rolled axles are determined, and loads and torques acting on the tools during rolling are estimated. An innovative concept of calibrating hollow axles by the rotary compression technique developed at the Lublin University of Technology is presented. Experimental tests of rolling solid axles in a 3-roll rolling mill (in a scale of 1:5) are performed, and basic force parameters of the rolling process are measured. Numerical and experimental loads and torques show a high agreement in terms of both quality and quantity.

scholarly journals The Effect of Process Parameters in Helical Rolling of Balls on the Quality of Products and the Forming Process

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2125 ◽  
Author(s):  
Janusz Tomczak ◽  
Zbigniew Pater ◽  
Tomasz Bulzak
Keyword(s):  
Metal Flow ◽  
Experimental Tests ◽  
Rolling Process ◽  
Helical Rolling ◽  
Forming Process ◽  
University Of Technology ◽  
Quality Of Products ◽  
Skew Rolling

This paper presents selected numerical and experimental results of a skew rolling process for producing balls using helical tools. The study investigates the effect of the billet’s initial temperature on the quality of produced balls and the rolling process itself. In addition, the effect of billet diameter on the quality of produced balls is investigated. Experimental tests were performed using a helical rolling mill available at the Lublin University of Technology. The experiments consisted of rolling 40 mm diameter balls with the use of two helical tools. To determine optimal rolling parameters ensuring the highest quality of produced balls, numerical modelling was performed using the finite element method in the Forge software. The numerical analysis involved the determination of metal flow kinematics, temperature and damage criterion distributions, as well as the measurement of variations in the force parameters. The results demonstrate that the highest quality balls are produced from billet preheated to approximately 1000 °C.

Influence of the Deformation Method on the Microstructure Changes in AZ31 Magnesium Alloy Round Rods Obtained by the Rolling Process

2016 ◽  
Vol 716 ◽  
pp. 864-870
Author(s):  
Andrzej Stefanik ◽  
Piotr Szota ◽  
Sebastian Mróz ◽  
Teresa Bajor ◽  
Sonia Boczkal
Keyword(s):  
Magnesium Alloy ◽  
Numerical Modelling ◽  
Rolling Mill ◽  
Laboratory Tests ◽  
Effective Strain ◽  
Rolling Process ◽  
Az31 Magnesium Alloy ◽  
Deformation Method ◽  
Microstructure Changes ◽  
Skew Rolling

This paper presents the research results of the microstructure changes of the round rods of AZ31 magnesium alloy in the hot rolling processes. The rolling was conducted in duo mill and a three-high skew rolling mill. Numerical modelling of the AZ31 magnesium alloy round rods rolling process was conducted using a computer program Forge 2011®. The verification of the results of numerical modelling was carried out during laboratory tests in a two-high rolling mill D150 and a three-high skew rolling mill RSP 40/14. Distributions of the total effective strain and temperature during AZ31 rods rolling process were determined on the basis of the theoretical analysis. Microstructure and texture changes during both analysed processes were studied.

The Method of Substitutive Circles Family: Application in Catia Design Environment for Gear Shaped Tool Profiling

2014 ◽  
Vol 1036 ◽  
pp. 370-375 ◽  
Author(s):  
Silviu Berbinschi ◽  
Gabriel Frumuşanu ◽  
Virgil Gabriel Teodor ◽  
Nicolae Oancea
Keyword(s):  
Numerical Data ◽  
Rolling Process ◽  
Design Environment ◽  
Complementary Method ◽  
Contact Points ◽  
Rolling Method ◽  
Graphical Algorithm

Tools which generate by enveloping using the rolling method may be profiled using various methods. The substitutive circles family method is a complementary method developed based a specifically theorem, in which is determined a family of circles associated with the blank’s centrode, family which envelop the profile to be generate. The method assumes the determination of the circles family, transposed in the rolling process between the blank and tool centrodes. In this paper is proposed an algorithm for curling surfaces in enveloping, associated with a pair of rolling circular centrodes. The graphical algorithm is based on the representation of the circles family enveloped the blank’s profile. It is generated the circles family transposed on the centrode associated with the gear shaped cutter and is determined a new position of contact points with the blank. The assembly of these points forms the profile of the gear shaped cutter. The numerical data proof the proposed method quality.

scholarly journals Numerical Analysis of a Skew Rolling Process for Producing a Stepped Hollow Shaft Made of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 61 (2) ◽  
pp. 677-682 ◽  
Author(s):  
Z. Pater ◽  
T. Bulzak ◽  
J. Tomczak
Keyword(s):  
Numerical Analysis ◽  
Thickness Distribution ◽  
Effective Strain ◽  
Rolling Process ◽  
Forming Process ◽  
Hollow Shaft ◽  
Wall Thickness Distribution ◽  
Light Trucks ◽  
Titanium Alloy Ti6al4v ◽  
Skew Rolling

Abstract The paper describes a rolling process for a hollow Ti6Al4V alloy shaft used in driving systems of light trucks. The shaft is formed by skew rolling using three tapered rolls. The principle of this forming process was discussed stressing its universality due to the potential of applying it for forming various products by one set of rolls. The numerical analysis results (product shape progression in rolling, wall thickness distribution, effective strain, temperature and variations in loads and torques) confirm that the proposed technique can be used for producing hollow long shafts.

scholarly journals NUMERICAL MODELING OF SKEW ROLLING PROCESS OF TWIST DRILLS

2016 ◽  
Vol 10 (32) ◽  
pp. 124-131 ◽  
Author(s):  
Tomasz Bulzak ◽  
Zbigniew Pater ◽  
Janusz Tomczak
Keyword(s):  
Numerical Modeling ◽  
Rolling Process ◽  
Skew Rolling ◽  
Twist Drills

scholarly journals Design and technological capabilities of a CNC skew rolling mill

2021 ◽  
Vol 21 (2) ◽  
Author(s):  
Janusz Tomczak ◽  
Zbigniew Pater ◽  
Tomasz Bulzak ◽  
Konrad Lis ◽  
Tomasz Kusiak ◽  
...  
Keyword(s):  
Rolling Mill ◽  
Performance Test ◽  
Metal Flow ◽  
Fem Analysis ◽  
Rolling Process ◽  
Design Solution ◽  
Test Results ◽  
Rolling Method ◽  
Mill Stand ◽  
Skew Rolling

AbstractResults of a study investigating a skew rolling process for elongated axisymmetric parts are presented. Despite the fact that the skew rolling technique for producing such parts was developed and implemented in the mid-twentieth century, there are no studies on this problem. The first part of this paper presents the results of FEM modelling of skew rolling stepped axles and shafts (solid and hollow). The FEM analysis was performed using the MSC Simufact Forming software. The numerical simulation involved the determination of metal flow patterns, the analysis of thermal parameters of the material during rolling, and the prediction of cracking by the Cockcroft-Latham ductile fracture criterion. Force parameters of rolling solid and hollow parts were also determined. The aim of the FEM analysis was to determine initial design assumptions and parameters for the development of the skew rolling mill. Later on in the paper, a design solution of a CNC skew rolling mill for rolling parts based on their envelope profile is proposed. FEM strength test results of a mill stand, obtained with MSC. NASTRAN, are presented. Finally, the performance test results of the constructed rolling mill are presented. The experiments involved rolling real stepped shafts that were modelled numerically. Obtained results show that the proposed skew rolling method has considerable potential. The designed and constructed rolling mill can be used to perform the rolling process according to the proposed method, with the tool and material kinematics being controlled based on the set parameters of a workpiece envelope.

scholarly journals Improving the X-ray Shielding Performance of Tungsten Thin-Film Plates Manufactured Using the Rolling Technology

2021 ◽  
Vol 11 (19) ◽  
pp. 9111
Author(s):  
Seon-Chil Kim
Keyword(s):  
Plate Thickness ◽  
Rolling Process ◽  
Radiation Shielding ◽  
Pure Tungsten ◽  
Peak Voltage ◽  
Cross Sectional ◽  
X Ray ◽  
Different Temperatures ◽  
Rolling Method ◽  
Rolling Technology

X-ray shields used for medical purposes are manufactured using lead, which is inexpensive and easy to manufacture. However, as lead can be a major factor contributing toward environmental contamination, such as lead poisoning, a radiation-shielding plate was manufactured in this study using a tungsten plate, an eco-friendly material, through a rolling process at different temperatures. In addition, the shielding plate produced via the hot-rolling method exhibited better shielding performance than that of the plate produced using the cold-rolling method, and the multilayer structure was well formed, as indicated in the cross-sectional image analysis. Upon applying a peak voltage of 100 kVp to the X-ray tube, the shielding performance observed was 80% and 96% when the plate thickness was 0.1 mm and 0.3 mm, respectively. Therefore, it is expected that, in the future, the pure tungsten-based shield presented in this study will replace lead plates, owing to its superior standardization and reproducibility of the shielding performance.

scholarly journals 2D cine vs. 3D free-breathing self-navigated whole heart for aortic root measurements in congenital heart disease

2021 ◽  
Vol 22 (Supplement_1) ◽  
Author(s):  
C Nussbaumer ◽  
J Bouchardy ◽  
C Blanche ◽  
D Piccini ◽  
AG Pavon ◽  
...  
Keyword(s):  
Congenital Heart Disease ◽  
Heart Disease ◽  
Aortic Root ◽  
Congenital Heart ◽  
Free Breathing ◽  
Maximum Diameter ◽  
Cross Sectional ◽  
Mean Diameter ◽  
Whole Heart

Abstract Funding Acknowledgements Type of funding sources: None. Background Cardiac magnetic resonance is considered the method of choice for determination of aortic root diameters in congenital heart disease. Usually, a cross-sectional 2D cine stack is acquired perpendicular to the vessel’s axis. However, this method requires a considerable patient collaboration and precise planning of image planes. This study compares a recently introduced free-breathing high-resolution 3D self-navigating whole heart sequence (3D self nav) to the 2D cine technique for determination of aortic root diameters. Methods Two observers measured on 2D cine and 3D self nav cross-sectional planes of the aortic root (figure A and B), acquired on a 1.5T scanner, cusp-commissure (CuCo) and cusp-cusp (CuCu) enddiastolic diameters (figure B and C). Asymmetry of the aortic root was evaluated by the ratio of the minimal to maximum CuCu diameter. CuCu diameters were compared to transthoracic echocardiographic (TTE) aortic root diameters. Results 65 exams in 58 patients (mean age 32 ± 15y) were included. 2D cine and 3D self nav spatial resolution was 1.4x4.5-6mm and 1.1³mm, respectively. 3D self nav and CuCu yielded larger diameters than 2D cine and CuCo, respectively (table). Intra- and interobserver variabilities were excellent for both techniques ( bias -0.5 to 1.0 mm). Intra-observer variability of the experienced observer was better for 3D self nav (F-test p < 0.05). Aortic root asymmetry was more pronounced in patients with bicuspid aortic valve (BAV: 0.73 (0.69; 0.78) vs. 0.93 (0.9; 0.96), p < 0.001), which was associated with a larger difference of maximum CuCu to TTE diameters: 5.5 ± 3.3 vs. 3.3 ± 3.8 mm, p = 0.03. Conclusion Both, the 3D self nav and 2D cine techniques allow reliable determination of aortic root diameters. However, the 3D self nav technique and measurement of the CuCu diameters should be privileged to avoid underestimation of the maximum diameter, particularly in patients with asymmetric aortic roots and/or BAV 2D cine vs. 3D self nav CuCo min CuCo mid CuCo max CuCu min CuCu mid CuCu max Mean diameter 2D cine (mm) 33.5 34.8 36.2 33.4 37.6 38.5 Mean diameter 3D self nav (mm) 34.5 35.9 37.2 34.3 38.5 39.7 Mean difference (mm) -1.0 -1.1 -1.0 -0.8 -1.3 -1.2 95% Limits of agreement (mm) -5.1 to 3.2 -5.3 to 3.1 -5.5 to 3.5 -5.5 to 3.8 -4.7 to 2.0 -4.7 to 2.3 Standard deviation (mm) 3.2 2.1 2.3 2.4 1.7 1.8 Variance (mm2) 4.5 4.5 5.2 5.6 2.9 3.2 Pearson’s correlation (r) 0.952 0.954 0.945 0.944 0.972 0.951 P value (t-test) 0.003 0.001 0.006 0.005 <0.001 <0.001 Abstract Figure.

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