scholarly journals Effect of Differential Speed Rotation Technology on the Forming Uniformity in Flexible Rolling Process

Materials ◽  
2018 ◽  
Vol 11 (10) ◽  
pp. 1906 ◽  
Author(s):  
Yi Li ◽  
Mingzhe Li ◽  
Kai Liu ◽  
Zhuo Li
Keyword(s):  
Element Model ◽  
Rolling Process ◽  
Metal Plate ◽  
Curved Surface ◽  
Forming Process ◽  
Surface Part ◽  
Flexible Rolling ◽  
Speed Rotation ◽  
The One ◽  
Differential Speed

As the local forming non-uniform of the formed curved surface part with larger bending deformation is the one of common defects, the utilization ratio of metal plate greatly reduces due to this defect, and cost of production is also increasing. In this paper, the differential speed rotation technology of flexible rolling process was proposed firstly to solve this forming defect. The finite element model was established, the reason of the local forming non-uniform was discussed; the effect of differential speed rotation technology on the forming uniform was studied. The results show that: Flexible rolling is a process based on thickness reduction, in this forming process, the thickness reduces sharply near the back end of metal plate, the local forming non-uniform of formed curved surface part is caused during this process; the differential speed rotation technology is applied in flexible rolling, with increasing rotation speed difference between upper and lower roll set, the forming uniformity of the formed curved surface part is greatly improved. The results of numerical simulation are in agreement with the result of forming experiments.

Analysis of Square Billet Cross Wedge Rolling Process Using Finite Element Method

2012 ◽  
Vol 271-272 ◽  
pp. 406-411 ◽  
Author(s):  
Wen Yu Ma ◽  
Bao Yu Wang ◽  
Jing Zhou ◽  
Qiao Yun Li
Keyword(s):  
Finite Element ◽  
Rolling Force ◽  
Element Model ◽  
Rolling Process ◽  
Simulation Software ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Radial Forces ◽  
Forming Angle ◽  
Deform 3D

The aim of this paper is to determine whether the train axle cross wedge rolling(CWR) using square billet as blank is available or not. Based on numerical simulation software DEFORM-3D, we built the finite element model. And the whole forming process was simulated successfully. The stress and strain distributions of workpiece in the process were analyzed. The effect of forming angle, stretching angle and billet size on rolling force was investigated, then determined the proper process parameters. The differences between the round billet rolling and the square billet rolling were obtained by comparing the tangential, axial and radial forces during the rolling process. The studied results show the availability of using square billet as blank in train axle CWR and provide important realistic meaning and application value.

Thermal Mechanical Coupled 3D Finite Element Simulation of Large H-Beam in Hot Rolling Process

2013 ◽  
Vol 281 ◽  
pp. 484-489
Author(s):  
Pei Qi Wang ◽  
Qin He Zhang ◽  
Bao Tian Dong ◽  
Ru Po Ma
Keyword(s):  
Finite Element ◽  
Rolling Force ◽  
Element Model ◽  
Rolling Process ◽  
Forming Process ◽  
Beam Production ◽  
Element Simulation ◽  
Simulation Results ◽  
Explicit Solver ◽  
H Beam

In order to research the forming process of H-beam, based on the large H-beam production line of HN600x200, the Standard and Explicit solver of ABAQUS are synthetically used to establish finite element model for rolling process and inter-pass thermolysis process. The reciprocation multi-pass rolling process simulation procedure based on the re-meshing technology is used to simulate the whole production process form blanks to finish products, and the continuity of data is ensured. Based on the simulation results, the deformation and rolling force of the roller as well as the metal flowing law and temperature field of workpiece are discussed emphatically. The results clearly show that the displacement of roller contains the elastic deformation and the deflection, and the counterforce of left adds to the counterforce of right is about equal to the resultant force. The simulation results are compared with the measuring results, which proves the correctness of simulation.

FEM Simulation of Laser Forming of Metal Plates*

2000 ◽  
Vol 123 (3) ◽  
pp. 405-410 ◽  
Author(s):  
G. Yu ◽  
K. Masubuchi ◽  
T. Maekawa ◽  
N. M. Patrikalakis
Keyword(s):  
Fem Simulation ◽  
Mesh Size ◽  
Element Model ◽  
Mechanical Analysis ◽  
Metal Plate ◽  
Laser Forming ◽  
Forming Process ◽  
Metal Plates ◽  
Simulation Time ◽  
Good Agreement

A finite element model is developed for thermo-mechanical analysis of the process of metal plate forming by laser line heating. A rezoning technique is adopted to greatly reduce the simulation time. The effects of the refinement of mesh size on temperature distribution and final distortion are studied. Comparison between numerical and experimental results shows a good agreement in final distortion of the formed plate. Finally, edge effects in the laser forming process are studied.

Flexible Rolling of Process Adapted Semi-Finished Parts and its Application in a Sheet-Bulk Metal Forming Process

2015 ◽  
Vol 639 ◽  
pp. 259-266 ◽  
Author(s):  
Philipp Hildenbrand ◽  
Thomas Schneider ◽  
Marion Merklein
Keyword(s):  
Sheet Thickness ◽  
Rolling Process ◽  
Forming Process ◽  
Flexible Rolling ◽  
Bulk Forming ◽  
Tailored Blanks ◽  
Metal Forming Process ◽  
Thickness Variations ◽  
Process Strategy ◽  
Functional Components

By applying bulk forming processes on sheet metals, thin-walled functional components with locally restricted wall thickness variations can be manufactured by forming operations. Using tailored blanks with a modified sheet thickness gradient instead of conventional blanks, an efficient controlling of the material flow can be achieved. One possible process to manufacture these semi-finished parts is a flexible rolling process. Based on an established process strategy new results for steels of differing strength and work-hardening behavior are presented in this paper. The influences of each material on the resulting process forces and blank properties regarding the same target geometry are discussed. The tailored blanks are hereby analyzed by their geometrical dimensions, like sheet thickness, and their mechanical properties, e.g. hardness distribution. Additionally, the possibilities of processing these tailored blanks in a deep-drawing and upsetting process are presented with a hereby focus on the residual formability of the tailored blanks.

The formation mechanism of protrusion of long thread by axial self-infeed rolling process

2020 ◽  
Vol 234 (10) ◽  
pp. 1302-1310 ◽  
Author(s):  
Shuowen Zhang ◽  
Shuqin Fan ◽  
Peng Zhang ◽  
Qian Zhu ◽  
Shengdun Zhao
Keyword(s):  
Formation Mechanism ◽  
Material Flow ◽  
Element Model ◽  
Rolling Process ◽  
Rolling Angle ◽  
Forming Process ◽  
Maximum Value ◽  
The Face ◽  
The Finite Element Model ◽  
Face Side

In the forming process of long threads by axial self-infeed rolling process, the protrusion generates on the top of the tooth profile, which affects the strength and precision of the formed threads. In this article, the principle of the axial self-infeed rolling process was described, and the finite element model was established to simulate the forming process of threads. The formation mechanism of protrusion was analyzed through material flow, which was verified by experiments. The pre-rolling angle and material’s influence on the protrusion size was also investigated. The results showed that the axial motion of the rollers squeezed one flank of the tooth, leading to higher protrusion on the face side as compared to the other side. During the rolling process, the height of the protrusion increased first and then decreased, reaching the maximum value when the height of the formed tooth was 73% of the whole tooth. In order to reduce the protrusion height, the pre-rolling angle should be 2°.

scholarly journals An Investigation into the Effect of Rolling Reduction on 3D Curved Parts Rolling Process

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1209
Author(s):  
Xiang Chang ◽  
Wenzhi Fu ◽  
Mingzhe Li ◽  
Xintong Wang ◽  
Weifeng Yang ◽  
...  
Keyword(s):  
Element Model ◽  
Rolling Process ◽  
Rolling Reduction ◽  
Shape Accuracy ◽  
Bending Deformation ◽  
Good Shape ◽  
Longitudinal Bending ◽  
Gap Height ◽  
Roll Gap ◽  
Forming Tools

Rolling technology based on arc-shaped rollers is a novel method for rapid manufacturing of 3D curved parts. The method uses a pair of arc-shaped rollers (a convex roller and a concave roller) as forming tools, forming an unevenly distributed roll gap. The sheet metal has both transverse bending and longitudinal uneven extension during rolling, so that surface parts with double curvature are processed. The curvature of the formed surface part can be changed by changing the rolling reduction. Changing the vertical distance between the rollers will cause the overall change of the roll gap height, which will inevitably have a great impact on the forming effect of formed 3D curved parts. In this paper, a finite element model and experiment with different rolling reductions was designed; the influence of rolling reduction on the bending deformation and shape accuracy of formed 3D curved parts was studied. The results show that, with the slight increase of rolling reduction (from 0.04 to 0.12 mm), the longitudinal bending deformation of the formed 3D curved part increases significantly, but its transversal bending is almost not affected. When the maximum rolling reduction is 0.04 and 0.06 mm (the corresponding minimum rolling reduction is less than or equal to zero), the shape accuracy of the formed 3D curved parts is not good enough; when the maximum rolling reduction is greater than 0.06 mm (the corresponding minimum rolling reduction is greater than zero), the shape accuracy of the formed 3D curved parts is significantly better. This indicates that, for the rolling of 3D curved parts based on arc-shaped rollers, ensuring that the minimum rolling reduction is greater than zero is the key to ensuring good shape accuracy of the formed 3D curved parts.

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.

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