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.

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.

Effects of Mandrel Structure on Ring Rolling Process for Large-Scale T-Sectioned Ring with Numerical Simulation

2013 ◽  
Vol 690-693 ◽  
pp. 2307-2310
Author(s):  
Ping Zhen Zhou ◽  
Li Wen Zhang ◽  
Sen Dong Gu ◽  
Hong Tao Duan ◽  
Li Hong Teng
Keyword(s):  
Numerical Simulation ◽  
Large Scale ◽  
Rolling Process ◽  
Ring Rolling ◽  
Small Ring ◽  
Rigid Plastic ◽  
Axial Ring ◽  
Folding Defect ◽  
Ring Rolling Process ◽  
Forming Defects

The process parameters including the mandrel structure of radial-axial ring rolling is in close relationship with the forming defects such as over-high axial spread and the folding defect in the connecting part of the big and small ring. In this paper, a 3D rigid-plastic and coupled thermal-mechanical finite-element model (FEM) of radial-axial ring rolling for large-scale T-sectioned ring was developed using commercial software of DEFORM-3D. By changing the chamfer radius of mandrel's work roll, the effects of mandrel structure on the height of axial spread which considerably affects the stability of the ring rolling process were investigated. The folding defect was also simulated. The numerical simulation results showed that with the decrement of the chamfer radius r, the metal increasingly accumulated in the big ring and the axial spread height increased. Consequently, the ring rolling process became unstable. Also, the folding angle augmented.

scholarly journals A Mandrel Feeding Strategy in Conical Ring Rolling Process

2014 ◽  
Vol 2014 ◽  
pp. 1-13
Author(s):  
Wen Meng ◽  
Guoqun Zhao ◽  
Yanjin Guan
Keyword(s):  
Feed Rate ◽  
Feeding Strategy ◽  
Simulation Method ◽  
Rolling Process ◽  
Ring Rolling ◽  
Fe Model ◽  
Die Structure ◽  
Value Range ◽  
Ring Rolling Process

A mathematical model for radial conical ring rolling with a closed die structure on the top and bottom of driven roll, simplified as RCRRCDS, was established. The plastic penetration and biting-in conditions in RCRRCDS process were determined. A mandrel feeding strategy for RCRRCDS process was proposed. The mandrel feed rate and its reasonable value range were deduced. The coupled thermal-mechanical FE model of RCRRCDS process was established. The reasonable value range of the mandrel feed rate was verified by using numerical simulation method. The results indicate that the reasonable value range of the mandrel feed rate is feasible, the proposed mandrel feeding strategy can realize a steady RCRRCDS process, and the forming quality of conical ring rolled by using the proposed feeding strategy is better than that of conical ring rolled by using a constant mandrel feed rate.

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.

Calculation of Axial Rolling Force in Radial-Axial Ring Rolling Process

2014 ◽  
Vol 1004-1005 ◽  
pp. 1344-1347 ◽  
Author(s):  
Tao Wang ◽  
Qiang Wang
Keyword(s):  
Rolling Force ◽  
Axial Direction ◽  
Rolling Process ◽  
Processing Parameters ◽  
Rolling Contact ◽  
Ring Rolling ◽  
Outer Diameter ◽  
Calculation Formula ◽  
Axial Ring ◽  
Ring Rolling Process

A mechanical model of axial ring rolling is established. According to the analytical method, the calculation formula of axial ring rolling contact area and unit rolling force is derived. On this basis the calculation formula of axial rolling force is derived. The influence of processing parameters on the axial rolling force is investigated. It is found that the axial rolling force increases with the increase of the outer diameter of ring, and the axial rolling force decreases with the increase of the inside diameter of ring. The greater the feed in axial direction, the greater the axial rolling force.

Calculation of Axial Rolling Torque in Radial-Axial Ring Rolling Process

2014 ◽  
Vol 633-634 ◽  
pp. 589-592
Author(s):  
Tao Wang ◽  
Qiang Wang
Keyword(s):  
Energy Method ◽  
Rolling Force ◽  
Axial Direction ◽  
Rolling Process ◽  
Processing Parameters ◽  
Ring Rolling ◽  
Outer Diameter ◽  
Axial Ring ◽  
Rolling Torque ◽  
Ring Rolling Process

The importance of the axial rolling torque to design equipment and process is described. On the basis of the established formula of axial rolling force, the formula of axial rolling torque is derived by using the moving volume theory of energy method. The influence of processing parameters on the axial rolling torque is investigated. It is found that the axial rolling torque increases with the increase of the outer diameter of ring, and the axial rolling torque decreases with the increase of the inside diameter of ring. The greater the feed in axial direction, the greater the axial rolling torque. The correctness of the formula is verified by calculating actual examples.

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.

A Comparison between Isothermal and Coupled Thermo-Mechanical FE Analyses of the Ring Rolling Process

2011 ◽  
Vol 264-265 ◽  
pp. 235-240
Author(s):  
Nassir Anjami ◽  
Ali Basti
Keyword(s):  
Finite Element ◽  
Rolling Process ◽  
Ring Rolling ◽  
Continuous Change ◽  
Rigid Plastic ◽  
Mechanical And Physical Properties ◽  
Prediction And Control ◽  
3D Deformation ◽  
Ring Rolling Process ◽  
And Control

Ring rolling process, especially hot rolling is characterized by 3D deformation, continuous change of thickness and height, high nonlinearity, non-steady flow and asymmetry. It involves both mechanical and thermal behaviors. Most mechanical and physical properties and boundary conditions are temperature related. The heat flow and stress analysis cannot be analyzed separately. In this study, both isothermal and coupled thermo-mechanical (CTM) 3D rigid-plastic finite element (FE) models of the hot ring rolling (HRR) process are developed to investigate their differences in accurately and quickly predicting the process. The results show that the latter should be more advantageous to the more accurate prediction and control of microstructure and properties of the ring.

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