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.

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.

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.

3-D Coupled Thermo-Mechanical FE Modelling and Simulation of Combined Ring Rolling

2012 ◽  
Vol 560-561 ◽  
pp. 1097-1102
Author(s):  
Zhi Qiang Zhang ◽  
Dong Sheng Qian ◽  
Lin Hua
Keyword(s):  
Rolling Process ◽  
High Energy ◽  
Poor Quality ◽  
Ring Rolling ◽  
Thick Wall ◽  
Fe Model ◽  
Fe Modelling ◽  
Deep Groove ◽  
Material Utilization ◽  
Temperature Force

Ring parts of duplicate gear, double-side flange, high pressure value body, are widely used in engineering machinery, have the common geometrical characteristic of thick-wall, small-hole and deep-groove on the surface. High energy consumption, low material utilization, low productivity and poor quality exist in the current forging technology of this type of rings. In this paper, a new forming method for this type of rings named combined ring rolling (CRR) is proposed. The forming principle of CRR is introduced at first, then, a 3-D coupled thermo-mechanical FE model for the CRR process of a double-side flange ring is developed. By simulation and analysis, the feasibility of CRR technology is testified, and the evolution and distribution rules of stain, temperature, force and power in the rolling process are revealed. The results provide the guideline for the research and development of CRR technology.

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 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.

Effect of Position between Upper Die and Workpiece on Cold Rotary Forging

2011 ◽  
Vol 189-193 ◽  
pp. 2547-2552 ◽  
Author(s):  
Xing Hui Han ◽  
Lin Hua
Keyword(s):  
Metal Forming ◽  
Interactive Effects ◽  
Fe Model ◽  
Software Environment ◽  
Forging Process ◽  
Rotary Forging ◽  
Forming Technology ◽  
Cylindrical Workpiece ◽  
Forging Force ◽  
Cold Rotary Forging

Cold rotary forging is an advanced but very complex incremental metal forming technology with multi-factors coupling interactive effects. The position between the upper die and the workpiece has a significant effect on the cold rotary forging process. In the current work, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of a cylindrical workpiece is developed under the ABAQUS software environment and its validity has been verified experimentally. On the basis of this reliable 3D FE model, the effects of the position between the upper die and the workpiece on the cold rotary forging process have been thoroughly revealed. The results show that with increasing the distance between the pivot point of the upper die and the centre of the workpiece, the deformation of the workpiece becomes more inhomogeneous and the maximum axial forging force and forging moment gradually increase. The results of this research not only provide valuable guidelines for the installation and adjustment of dies in the cold rotary forging process, but also help to better understand the deformation mechanisms of cold rotary forging.

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.

Experimental Investigation and Research on Forming Process of Micro Flat-Wire

2010 ◽  
Vol 37-38 ◽  
pp. 417-423
Author(s):  
Chun Chiu Fok ◽  
Zhong Ning Guo ◽  
Zhao Qin Yu ◽  
Jian Wen He
Keyword(s):  
Rolling Process ◽  
Rolling Speed ◽  
Roll Forming ◽  
Wire Surface ◽  
Forming Process ◽  
Forming Technology ◽  
Rolling Method ◽  
The Wire ◽  
Roll Gap ◽  
Control Part

The aim of this study is to get a better understanding of Micro Flat-Wire Roll Forming Technology. There are three methods for Mirco flat-wire forming, i.e., drawing, extrusion, and rolling. Without replacing the equipment, rolling method only demands to adjust the relative roll gap between the pressure and the wire deformation that it can produce different specifications of mirco flat-wire. The rolling equipment was introduced and can be divided into three parts, the mechanism section, the control part and the wire-locating device. Furthermore, the rolling process parameters were summarized as well. The effect of rolling amount and rolling speed on the wire surface quality was also discussed.

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