scholarly journals Research on forming technology of rotary forging with double symmetry rolls of large diameter : thickness ratio discs

2021 ◽  
Vol 12 (1) ◽  
pp. 625-638
Author(s):  
Rong Fei Ma ◽  
Chun Dong Zhu ◽  
Yu Fan Gao ◽  
Zi Hao Wei
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Large Diameter ◽  
Thickness Ratio ◽  
Forming Process ◽  
Rigid Plastic ◽  
Local Pressure ◽  
Rotary Forging ◽  
Forming Technology ◽  
Double Symmetry

Abstract. Rotary forging with double symmetry rolls (DSRs) is a new metal plastic forming technology developed on the basis of conventional rotary forging with a single roll, which uses a pair of symmetrical cone rolls to realize continuous local pressure plastic deformation of the workpiece. Large-diameter, thin discs are a key component in nuclear power, aerospace, deep-sea exploration, and other fields. At present, the forming process of large-diameter discs mainly includes welding and multiple local upsetting, but these processes exhibit many defects and can not meet the requirements of industry. In this paper, a large diameter : thickness ratio disc is integrally formed by rotary forging with DSRs. Using theoretical calculation and finite element simulation methods, the stable rolling conditions and calculation formulas of force and power parameters of rotary forging with DSRs of a large diameter : thickness ratio disc are derived. Based on the reliable three-dimensional rigid-plastic finite element model, the plastic deformation characteristics of rotary forging with DSRs of discs are studied, the reliability of the stable rolling conditions and the calculation formulas of force and power parameters are verified, and the defects and causes of unstable rolling conditions are analysed. An experiment was carried out on a rotary forging press developed with double symmetry rolls, and the experimental results are in good agreement with simulation results, which demonstrated that rotary forging with DSRs is a reliable technology for forming large diameter : thickness ratio discs. The results of this research are helpful to promote the further development of rotary forging with DSRs.

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.

The Finite Element Simulation Used in Straight Tooth Bevel Gear’s Vibration Rotary Forging

2012 ◽  
Vol 430-432 ◽  
pp. 1716-1720
Author(s):  
Gai Pin Cai ◽  
Xiao Hui Zhao ◽  
Hong Tao Su
Keyword(s):  
Finite Element ◽  
Metal Flow ◽  
Bevel Gear ◽  
Forming Process ◽  
Rigid Plastic ◽  
Element Analysis ◽  
Rotary Forging ◽  
Bevel Gears ◽  
Element Simulation ◽  
Vibration Parameters

Vibration rotary forging is a complex precision forming process. In the forming process, the addition of the vibration make the boundary condition and the friction condition of the gear blank and the mould changed with the rotation of the head, which lead the forming process of the spur bevel gears become more complicated. Using the rigid-plastic finite element method to study the metal flow law and the stress distribution of the gear blank during the forming process of the spur bevel gears. Using the DEFORM-3D finite element analysis software to simulate and analysis the forming process of the spur bevel gear, in order to get the forming law of the bevel gear during the different type of the vibration parameters.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

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.

Finite Element Analyses of Elasto-Plastic Deformation in Pearlite Lamellar and Colony Structures

2014 ◽  
Vol 626 ◽  
pp. 307-310 ◽  
Author(s):  
Roslan Lidyana ◽  
Tetsuya Ohashi ◽  
Yohei Yasuda ◽  
Kohsuke Takahashi ◽  
Chikara Suruga
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Plastic Strain ◽  
Thickness Ratio ◽  
Lamellar Thickness ◽  
Finite Element Analyses ◽  
Lamellar Orientation ◽  
The Difference

Elasto-plastic tensile deformations in pearlite lamellar and two-colony structures are studied by finite element analyses to investigate the effects of lamellar thickness ratio and difference of lamellae orientation of two colonies in pearlite microstructure. The results obtained from plastic strain distributions in lamellar and colony structures show that plastic deformation in cementite lamellar stabilized when ferrite lamellar is thicker than cementite lamellar thickness and plastic strain concentrates when the difference between cementite lamellar orientation in two colonies are larger than 45°.

Numerical and Experimental Investigation of Bump Foil Forming Process for Foil Air Bearings

2011 ◽  
Vol 204-210 ◽  
pp. 2103-2108
Author(s):  
Wen Bo Duan ◽  
Hai Peng Geng ◽  
Bai Song Yang ◽  
Yan Hua Sun ◽  
Lie Yu
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Deformable Body ◽  
Friction Model ◽  
Nonlinear Finite Element ◽  
Air Bearings ◽  
Forming Process ◽  
Rigid Plastic ◽  
Friction Forces ◽  
Simulation Results

In this paper, a simplified nonlinear finite element for bump foil forming process of foil air bearings is developed. The bump foil is dealt with as flexible deformable body, the upper die and lower die are considered as the rigid body without deformation. The friction model between bump foil and dies with velocity-dependent friction forces is described by arctan function. The forming process of SS304 Stainless Steel bump foil under different loads is investigated with rigid-plastic finite element method. The simulation results are compared with theoretical values and experimental results. Therefore more feasible process parameters are obtained to fabricate the bump foils.

scholarly journals Forming Characteristics and Mechanism of Double-roll Rotary forging for Large Diameter and Thin-walled Metal Discs

2021 ◽  
Author(s):  
Zhongquan Yu ◽  
Chundong Zhu ◽  
Mingchao Chen ◽  
Site Luo
Keyword(s):  
High Surface ◽  
Large Diameter ◽  
Equivalent Stress ◽  
Low Noise ◽  
Forming Process ◽  
Eccentric Load ◽  
Geometric Shapes ◽  
Rotary Forging ◽  
Forming Characteristics ◽  
Thin Walled

Abstract Double-roll rotary forging is an emerging plastic forming technology based on rotary forging. Owing to the advantages of labor saving, small eccentric load, low noise and vibration, good uniformity, high surface quality and material saving, it is very promising for fabrication of large-diameter thin-walled disc. To date, few relevant research on the double-roll rotary forging technology of large-diameter thin-walled metal discs has been reported, and the forming mechanisms and process of disc workpieces remains uninvestigated. Herein, a 3D rigid-plastic finite element model (FEM) is established to simulate the fabrication process of large-diameter thin-walled disc, four geometric features appear in the forming process: “mushroom” shape, “upper drum” shape, “drum shape” shape and “lower drum” shape. Equivalent stress, equivalent strain and temperature field of these four geometric shapes are analyzed, and the forming mechanism of these four geometric shapes is revealed. The reliability and accuracy of FEM are verified through experiments and the four geometric shape features occur in the process are consistent with the simulation. The research results provide valuable guidelines for better understanding of double-roll rotary forging for the fabrication of large-diameter thin-walled discs.

Some Plastic Deformation Modes for Indentation of Half Space by a Rigid Body With Serrated Surface as a Model of Roughness Transfer in Metal Forming

2002 ◽  
Vol 124 (2) ◽  
pp. 146-151 ◽  
Author(s):  
Jingyu Shi ◽  
D. L. S. McElwain ◽  
S. A. Domanti
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Free Surface ◽  
Rigid Body ◽  
Half Space ◽  
Metal Forming ◽  
Forming Process ◽  
Perfectly Plastic ◽  
Metal Forming Process ◽  
Deformation Modes

This paper is concerned with the plastic deformation modes of the free surface of the half space between the teeth on the serrated surface of a rigid body. The rigid body indents the half space perpendicularly and the material of the half space is assumed to be elastic/rigid perfectly plastic. Plane-strain conditions are assumed. The emphasis in this paper is on the profile left on the surfaces of the material when the indentation proceeds to some depth and then the indenter is removed. Based on the observations from finite element results, slip line fields for the plastic deformation regions at various stages of indentation are proposed and the corresponding hodographs for the velocity field are presented. This has application in roughness transfer of final metal forming process.

Deformation Characteristic Analysis on Air Bending in JCO Forming of Large Diameter Welding Pipe

2014 ◽  
Vol 623 ◽  
pp. 113-116
Author(s):  
Li Feng Fan ◽  
Ying Gao ◽  
Jia Xin Yan ◽  
Jian Bin Yun
Keyword(s):  
Finite Element ◽  
Large Diameter ◽  
Deformation Characteristic ◽  
Characteristic Analysis ◽  
Forming Process ◽  
Forming Quality ◽  
Air Bending ◽  
Welding Pipe ◽  
X80 Steel ◽  
Submerged Arc

JCO forming is one of manufacture mode widely used in production of large diameter submerged-arc welding pipes, in which JCO forming process is progressive multi-step air bending. In order to improve JCO forming quality, it is necessary to analysis deformation characteristic of air bending. So, air bending is analyzed using finite element method. Taking the air bending of X80 steel Φ1219mm×22mm×12000mm welding pipe for instance, the air bending is simulated by finite element (FE) code ABAQUS. In this paper, the simulation data is validated by experiments and a comparison showed a good agreement with experiments results. The stress/strain from simulation is discussed. Thus, the results of research provides a basis to improve JCO forming quality.

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