3D FE Modeling of Three Rolls Cross Rolling Process of a Rotary Disk Part

2011 ◽  
Vol 189-193 ◽  
pp. 1991-1996 ◽  
Author(s):  
Xiu Mei Zhou ◽  
Lin Hua ◽  
Dong Sheng Qian
Keyword(s):  
Rolling Force ◽  
Rolling Process ◽  
Fe Model ◽  
Forming Process ◽  
Software Environment ◽  
Cross Rolling ◽  
Rolling Technique ◽  
Rotary Disk ◽  
Rotary Parts ◽  
Plastic Forming

Special rolling is also called rotary forming process, which is an advanced manufacture technology of making workpiece generate deformation in a rotary state by continuous local plastic forming. Disk rotary parts with outer stepped cross-section, such as wheels, flanges, valves and so on, are widely used in engineering machinery. Traditionally, this kind of part is manufactured by forging and cutting, which consumes a lot of energy and materials especially to the large size part. In this paper, a new specific rolling technique called three rolls cross rolling is first presented to produce this kind of part, and the principle and characteristics of this technique are described in detail. Then, base on the principle of the three rolls cross rolling, a 3D coupled thermo-mechanical FE model is developed under ABAQUS software environment. As a result, under the simulation and analyses of a real example, the feasibility of this technique is verified, and the evolutional laws of the strain, temperature and rolling force and power parameters during the process are investigated as well. The obtained results provide valuable guidelines for the further investigation on the forming characteristic of the three rolls cross rolling technique.

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.

scholarly journals A New Method of Manufacturing Hollow Shafts via Flexible Skew Rolling

2021 ◽  
Vol 2101 (1) ◽  
pp. 012010
Author(s):  
Xiaoqing Cao ◽  
Baoyu Wang ◽  
Wei Guo ◽  
Zhidong Ju
Keyword(s):  
Rolling Force ◽  
Rolling Process ◽  
Fe Model ◽  
Forming Process ◽  
Hollow Shaft ◽  
Process Adjustment ◽  
Rolling Load ◽  
Rolling Torque ◽  
Skew Rolling ◽  
Hollow Shafts

Abstract The existing rolling process of large and long axle parts, such as the cross wedge rolling (CWR) process, requires special molds and larger equipment. Flexible skew rolling (FSR) hollow shafts with mandrel is a near net-shape rolling technology which can achieve the diversified production of rolled parts without special molds. It has significant advantages such as small equipment tonnage, small die size, low rolling load, simple process adjustment, and especially suitable for multi-variety and small-batch production. This paper proposes hollow train shafts formed by FSR with mandrel. Reasonable parameters were selected for experiments, and the forming process was calculated by finite element (FE) software. The experimental results are consistent with the simulation results, indicating that the FE model is reliable. The rolling force and rolling torque are analyzed by simulation. Finally, the microstructure of different positions of the rolled-piece is analyzed, and the microstructure of the rolled part is refined. It is provide a feasible scheme for the rolling of large hollow shaft parts.

Numerical Simulation of GH4169 Alloy Section of Hot Roll Forming

2014 ◽  
Vol 904 ◽  
pp. 479-482
Author(s):  
Lei Gao ◽  
Yu Hua Pang ◽  
Lie Sun ◽  
Da Rong Tian
Keyword(s):  
Surface Temperature ◽  
Rolling Force ◽  
Effective Strain ◽  
Rolling Process ◽  
Roll Forming ◽  
Structure Property ◽  
Forming Process ◽  
Rigid Plastic ◽  
Roll Forming Process ◽  
Gh4169 Alloy

A hot roll forming process of GH4169 alloy complex sections described in this paper is a new forming process of GH4169 alloy sections. The rolling 6o, 7o, 8o pass and rectangular, wedge-shaped, irregular blank are designed. Rolling models has been developed using the rigid-plastic finite element method on DEFORM. The rolling force and pass fullness and the distribution of various field-variables such as temperature and effective strain can be obtained from the simulated result. The finally optimizing rolling process shows that the pass slopes with 6o on the roll, the cross-section of the blank is irregular, and the rolling processes are using one pass to do two passes rolling through changing the value of the roll gauge. The simulated results show the temperature of the workpiece is about 1030~1080°C, the inner temperature is greater than the surface temperature, the surface temperature is minimum, and the effective strain is about 0.3~2, which meet the requirement of the GH4169 alloy structure property, and they are significance to the other hot roll forming process of GH4169 alloy sections.

Application of a Material Model to Predict Rolling Forces and Microstructure during a Hot Ring Rolling Process

2013 ◽  
Vol 762 ◽  
pp. 354-359 ◽  
Author(s):  
Thomas Henke ◽  
Gerhard Hirt ◽  
Markus Bambach
Keyword(s):  
Grain Size ◽  
Microstructure Evolution ◽  
Rolling Force ◽  
Flow Behavior ◽  
Rolling Process ◽  
Ring Rolling ◽  
Experimental Investigations ◽  
Forming Process ◽  
Ring Geometry ◽  
Ring Rolling Process

Ring rolling is an incremental bulk forming process. Hence, the process consists of a large number of alternating deformations and dwell steps. For accurate calculations of material flow and thus ring geometry and rolling forces in hot ring rolling processes, it seems necessary to consider material softening due to static and post dynamic recrystallization which could occur between two deformation steps. In addition, due to the large number of cycles, the modeling results, especially the prediction of grain size, can easily be affected by uncertainties in the input data. However, for small rings and ring material with slow recrystallization kinetics, the interpass times can be short compared to the softening kinetics and the effect of softening can be so small, that microstructure evolution and the description of the materials flow behavior can be de-coupled. In this paper, a semi-empirical JMAK-based model for a stainless steel (1.4301/ X5CrNi18-9/ AISI304) is presented and evaluated by the use of experiments and other investigations published in [1],[2]. Finite Element (FE) simulations of a ring rolling process with a high number of ring revolutions and thus multiple, incremental forming steps were conducted based on ring rolling experiments. The FE simulation results were validated with the experimentally derived rolling force and evolution of ring diameter. The microstructure evolution was calculated in a post processing step considering the investigated evolution of strain and temperature. In this calculation the interrelations between the fraction of dynamically recrystallized microstructure, the evolution of post-dynamically recrystallized microstructure and the final grain size have been considered. Both, the calculated final microstructure and the evolution of rolling force and ring geometry calculated stand in good agreement with the experimental investigations.

Determining and Optimizing of Guide Rolls Motion Track in Cold Ring Rolling Process

2006 ◽  
Vol 532-533 ◽  
pp. 141-144 ◽  
Author(s):  
Zhi Chao Sun ◽  
He Yang ◽  
Lan Yun Li
Keyword(s):  
Functional Relationship ◽  
Rolling Force ◽  
Rolling Process ◽  
Initial Position ◽  
Ring Rolling ◽  
Software Environment ◽  
Cold Ring Rolling ◽  
The Stability ◽  
Ring Rolling Process ◽  
And Control

Guide rolls play an important role in controlling both the ring circularity and the stability of cold ring rolling process. However, it is difficult to predict and control the motion of the guide rolls due to the complexity of process associated with the coupled effects of multi-factors. In this paper, a reasonable controlling model of the guide rolls is proposed, and the functional relationship between the motion track of the guide rolls and their setup parameters and process ones is established, by which the guide rolls motion track can be determined. On this basis, a 3D-FE simulation model for cold ring rolling is developed under the ABAQUS software environment and the effects of the initial position and motion track of the guide rolls on the forming stability, ring circularity, rolling force, and oscillating are investigated. Taking the forming stability and ring circularity as objects, the optimum initial position and motion track of the guide rolls are obtained.

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.

Study on Load of Hollow Motor Shaft by 4-Roll Cross Wedge Rolling

2013 ◽  
Vol 288 ◽  
pp. 267-270 ◽  
Author(s):  
Yong Ming Yang ◽  
Feng Wen Cheng ◽  
Jiu Chuan Chen ◽  
Jun Zhao
Keyword(s):  
Rolling Force ◽  
Rolling Process ◽  
Fe Model ◽  
Motor Shaft ◽  
Cross Wedge Rolling ◽  
Mill Equipment ◽  
Die Structure ◽  
Forming Analysis ◽  
Rolling Load ◽  
Deform 3D

Rolling force is the main parameters for calculating the intensity and rigidity of the main parts in the mill. To determine the force produced by the four roll rolling process, the finite element (FE) model for hollow motor shaft forming using 4-roll cross wedge rolling had been established for forming analysis with the aid of FE software Deform-3D. According to the results of FE simulation, the rolling load rules were obtained and maximum force of up to 60 KN. It has important theoretical significance and application value for the mill equipment designing and die structure optimization.

Mechanics Analysis and Numerical Simulation on the Precise Forming Process of Spline Cold Rolling

2008 ◽  
Vol 575-578 ◽  
pp. 416-421 ◽  
Author(s):  
Yong Tang Li ◽  
Jian Li Song ◽  
Da Wei Zhang ◽  
Quan Gang Zheng
Keyword(s):  
Numerical Simulation ◽  
Cold Rolling ◽  
Theoretical Basis ◽  
Rolling Force ◽  
Rolling Process ◽  
Average Pressure ◽  
Forming Process ◽  
Mechanics Analysis ◽  
Simulation And Experiment ◽  
Set Up

The forming process of spline cold rolling was analyzed. The unit average pressure, contact area and rolling force in the cold rolling precision forming process were analyzed and solved. The mechanical and mathematical model has been set up on the basis of the analysis. The numerical simulation of spline cold rolling process was carried out. The results obtained by comparison of theoretical analysis, numerical simulation and experiment provide a theoretical basis for the study and application of spline cold rolling process.

The Effect of the Initial Temperature of Ring Blank on Conical Ring Rolling Process

2014 ◽  
Vol 597 ◽  
pp. 266-271
Author(s):  
Wen Meng ◽  
Guo Qun Zhao ◽  
Yan Jin Guan
Keyword(s):  
Temperature Distribution ◽  
Initial Temperature ◽  
Rolling Force ◽  
Rolling Process ◽  
Ring Rolling ◽  
Fe Model ◽  
Rolling Moment ◽  
Rolled Ring ◽  
Ring Rolling Process ◽  
Ring Blank

A FE model of radial conical ring rolling process with a closed die structure on the top and bottom part of driven roll (RCRRCDS) process was set up based on ABAQUS/Explicit software. The effect of the initial temperature of conical ring blank on equivalent plastic strain (PEEQ) and temperature distribution of rolled ring, average rolling force and average rolling moment was investigated. The results indicated that with the increase of the initial temperature of ring blank, the PEEQ distribution of rolled ring becomes uniform at first and then less uniform; the temperature distribution gradually becomes homogeneous; and both average rolling force and average rolling moment decrease. When the initial temperature of ring blank is 925°C, the PEEQ distribution of rolled ring is most uniform; the temperature distribution of rolled ring is relatively uniform; the average rolling force and average rolling moment are relatively smaller.

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.

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