Relationship between Hardness and Deformation during Cold Rolling Process of Complex Profles

The hardening on surface of complex profles such as thread and spline manufactured by cold rolling can efectively improve the mechanical properties and surface quality of rolled parts. The distribution of hardness in superfcial layer is closely related to the deformation by rolling. To establish the suitable correlation model for describing the relationship between strain and hardness during cold rolling forming process of complex profles is helpful to the optimization of rolling parameters and improvement of rolling process. In this study, a physical analog experiment refecting the uneven deformation during complex-profle rolling process has been extracted and designed, and then the large date set (more than 400 data points) of training samples refecting the local deformation characteristics of complexprofle rolling have been obtained. Several types of polynomials and power functions were adopted in regression analysis, and the regression correlation models of 45# steel were evaluated by the single-pass and multi-pass physical analog experiments and the complex-profle rolling experiment. The results indicated that the predicting accuracy of polynomial regression model is better in the strain range (i.e., ε < 1.2) of training samples, and the correlation relationship between strain and hardness out strain range (i.e., ε > 1.2) of training samples can be well described by power regression model;so the correlation relationship between strain and hardness during complex-profle rolling process of 45# steel can be characterized by a segmented function such as third-order polynomial in the range ε < 1.2 and power function with a ftting constant in the range ε > 1.2;and the predicting error of the regression model by segmented function is less than 10%.

Remote open-path laser-induced breakdown spectroscopy for the analysis of manganese in steel samples at high temperature

A remote open-path laser-induced breakdown spectroscopy(LIBS) system was designed and studied in the present work for the purpose of combining the LIBS technique with the steel production line. In this system, the relatively simple configuration and optics were employed to measure the steel samples at a remote distance and a hot sample temperature. The system has obtained a robustness for the deviation of the sample position because of the open-path and alloptical structure. The measurement was carried out at different sample temperatures by placing the samples in a muffle furnace with a window in the front door. The results show that the intensity of the spectral lines increased as the sample temperature increased. The influence of the sample temperature on the quantitative analysis of manganese in the steel samples was investigated by measuring ten standard steel samples at different temperatures. Three samples were selected as the test sample for the simulation measurement. The results show that, at the sample temperature of 500 ℃, the average relative error of prediction is 3.1% and the average relative standard deviation is 7.7%, respectively.

Research on Combined Hot Extrusion Forming Process of Alternator Poles

Based on the structure analysis of alternator poles, two closed die forging steps in one heat forming process of alternator poles were put forward, as well as the forming die system. Firstly, a thicker bottom base of alternator poles was per-formed by radial forging, then the middle boss and pole claw were forming on the bottom base by backward extrusion. A 3-D coupled thermo-mechanical finite element model was created. The billet deformation, metal flow and forming load were obtained. The results showed that a filling well forging without overlap defects could be obtained by this process, and that?the forming load at the first step increased slowly, but the load increased sharply at the second step when the middle boss was filling completely by the former process. An improved process was put forward, which changed the flow mode in the second forging step, it can considerably reduce the final forging load.

Characteristics of surface and subsurface of formed thread parts by axial-infeed thread rolling process

The thread rolling process has been widely applied to manufacture high-performance thread parts.In this process,the evolutions of surface and subsurface are frequently introduced,which affect the working performance of manufactured parts.In this study,an axial-infeed thread rolling process(ATRP)is employed,and the macro-meso surface characteristics under different lubrications and operating conditions are investigated.Moreover,the distributions of microstructure and hardness on the subsurface of formed tooth are analyzed in detail,along with the study of stress state and yield strength change.It is found that the MoS_(2)grease is more effective in reducing the surface roughness and defects than the lubrication oil and water-base graphite during the ATRP process.Increasing rolling speed improves the quality of surface morphology and can reduce the surface roughness.On the subsurface of bottom and flank,intensive shear stress occurs in a narrow region,resulting in the elongation and refinement of the grains and increasing the low angle grain boundary fraction.Based on the grain size and plastic strain,the yield strength is predicted.The maximum yield strength and hardness on the bottom of formed tooth are improved by 41.2% and 39.4%,respectively.

Frictional behavior during cold ring compression process of aluminum alloy 5052

The friction is the considerable boundary condition in bulk metal forming.In this paper,the ring compression test was used to evaluate the friction coefficient and factor in Coulomb friction model and Tresca friction model for the plastic deformation of aluminum alloy AA5052.The micro-macro analysis method combining surface morphology and micro-texture was used to explore the friction behaviors in AA5052 cold forming process.In general,the magnitude(μor m)of friction changes before and after a deformation threshold during ring compression.The maximum change rate of the magnitude(μor m)before and after the deformation threshold is close to 18.5%under the present experimental conditions,and the change rate decreases with increasing loading speed.The lubrication using MoS_(2) is better than that using oil at lower speeds(0.15 mm/s,1.5 mm/s),but the lubrications for MoS_(2) and oil are similar at higher speeds(15 mm/s).The surface roughness,three-dimensional topography,and surface texture of compressed ring have a sudden change around the deformation threshold,which deviate from the previous evolution trend.The increased friction after deformation threshold also promotes the formation of sufficient shear strain layer in the subsurface plane of the compressed ring,and then it hinders the formation of the typical deformation textures withβ-oriented line and promotes the appearance of shear textures such as{001}(110),{111}(uvw)and{hkl}{110)textures.

Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts

Counter-roller spinning (CRS), where the mandrel is replaced by rollers, is an effective means of manufacturing large-sized, thin-walled, cylindrical parts with more than 2500 mm diameter. CRS is very complex because of multi-axis rotation, multi-local loading along the circumference, and radial-axial compound deformation. Analytical or experimental methods cannot fully understand CRS. Meanwhile, numerical simulation is an adequate approach to investigate CRS with comprehensive understanding and a low cost. Thus, a finite element (FE) model of CRS was developed with the FORGE code via meshing technology, material modeling, determining the friction condition, and so on. The local fine mesh moving with the roller is one of highlights of the model. The developed 3D-FE model was validated through a CRS experiment by using a tubular blank with a 720 mm outer diameter. The developed 3D-FE model of CRS can provide a basis for parameter optimization, process control, die design, and so on. The data on force and energy predicted by the 3D-FE model can offer reasonable suggestions for determining the main mechanical parameters of CRS machines and selecting the motors. With the predicted data, an all-electric servo-drive system/machine with distributed power was designed in this work for CRS with four pairs of rollers to manufacture a large-sized, thinwalled, cylindrical part with 6000 mm diameter.

Variation of the friction conditions in cold ring compression tests of medium carbon steel

Lubrication and friction conditions vary with deformation during metal forming processes.Significant macro-variations can be observed when a threshold of deformation is reached.This study shows that during the cold compression processing of#45(AISI 1045)steel rings,the magnitude of friction and surface roughness(Ra)changes significantly upon reaching a 45%reduction in ring height.For example,the Ra of compressed ring specimens increased by approximately 55%immediately before and after reaching this threshold,compared to an 18% or 25%variation over a 35%-45%or a 45%-55%reduction in height,respectively.The ring compression test conducted by this study indicates that the Coulomb friction coefficient and Tresca friction factor mare 0.105 and 0.22,respectively,when the reduction in height is less than 45%;and 0.11 and 0.24,respectively,when the reduction in height is greater than 45%.

Effects of sheet thickness and material on the mechanical properties of flat clinched joint

The flat clinching process is attracting a growing attention in the joining field of lightweight materials because it avoids the geometric protrusion that appears in the conventional clinching process. In this paper, the effects of sheet thickness and material on the mechanical properties of the clinched joint were studied. Al1060 and Al2024 sheets with 2 mm thickness were employed to develop the clinched joint by using different material configurations, and Al1060 sheets with 2.5- and 1.5-mm thicknesses were used to produce the clinched joint by using different thickness configurations. The clinched joints using various sheet configurations were sectioned, and dimensional analysis was conducted. Cross-tensile and shearing tests were carried out to analyze the mechanical properties of the clinched joint, including tensile strength, shearing strength, and absorbed energy. In addition, the failure modes of the clinched joints were discussed. Results indicated that the clinched joint with a stiff top sheet had increased static strength regardless of the test type. The clinched joint with a thick top sheet demonstrated lower static strength than the joint with a thick bottom sheet in the cross-tensile test. However, this result was reversed in the shearing tests. The flat clinching process has a great potential in joining dissimilar and various thickness materials.