As the traditional forging process has many problems such as low efficiency, high consumption of material and energy, large cylindrical shell rolling is introduced. Large cylindrical shell rolling is a typical rotary ...As the traditional forging process has many problems such as low efficiency, high consumption of material and energy, large cylindrical shell rolling is introduced. Large cylindrical shell rolling is a typical rotary forming technology, and the upper and lower rolls have different radii and speeds. To quickly predict the three-dimensional stresses and eliminate fishtail defect, an improved strip layer method is developed, in which the asymmetry of the upper and lower rolls, non-uniform deformation and stress, as well as the asymmetrical spread on the end surface are considered. The deformation zone is divided into a certain number of layers and strips along the thickness and width, respectively. The transverse displacement model is constructed by polynomial function, in order to increase the computation speed greatly. From the metal plastic mechanics principle, the three-dimensional stress models are established. The genetic algorithm is used for optimization calculation in an industrial experiment example. The results show that the rolling pressure, the normal stresses, the upper and lower friction stress distributions are not similar with those of a general plate rolling. There are two relative maximum values in rolling pressure distribution. The upper and lower longitudinal friction stresses change direction nearby the upper and lower neutral points, respectively. The fishtail profile of spread on the end surface is predicted satisfactorily. The reduction could be helpful to eliminate fishtail defect. The large cylindrical shell rolling example illustrates the calculation results acquired rapidly are good agreements with the finite element simulation and experimental values of previous study. A highly effective and reliable three-dimensional simulation method is proposed for large cylindrical shell rolling and other asymmetrical rolling.展开更多
The present study aimed to determine the optimum rolling speed for break-down rolling of as-cast AZ31 B alloy and investigated the friction behavior associated with temperature-and reduction-sensitivity at the roll/pl...The present study aimed to determine the optimum rolling speed for break-down rolling of as-cast AZ31 B alloy and investigated the friction behavior associated with temperature-and reduction-sensitivity at the roll/plate contact interface. Tensile testing, formability evaluation and microstructural studies relevant to different rolling speeds were performed and finally the optimum operating rolling speed（50.0 ± 0.8 m/min） was obtained. Further, the effects of rolling reduction and initial temperature were assessed on the temperature variation, lateral spread and interfacial friction behavior at optimum rolling speed. The results showed that lower rolling speed（18.0 ± 0.8 m/min） resulted in an incompletely recrystallized structure where twins occupied relatively high volume fraction. Twinning dominated the deformation at rolling speed exceeding the optimum, resulting in the local recrystallization with shear bands and coarse grains. Rolling at 50.0 ± 0.8 m/min could get the best overall tensile properties and rolling formability due to the relatively high recrystallization degree and microstructure uniformity. An inverse method has been developed to determine the interfacial friction coefficient during interaction of AZ31 B alloy with roll surfaces. When rolling at the optimum speed, the interfacial friction coefficient ranged from 0.16 to 0.58, which was strongly positively correlated with the reduction but slightly positively correlated with the initial temperature. Depended on the rolling characteristics, external friction effect coefficient ranged from 1.25 to 2.35 and it exhibited positive correlation with both the initial rolling temperature and rolling reduction.展开更多
基金Supported by National Science and Technology Major Project of China(Grant No.2011ZX04002-101)National Science and Technology Support Plan of China(Grant No.2011BAF15B02)National Natural Science Foundation of China(Grant No.51305388)
文摘As the traditional forging process has many problems such as low efficiency, high consumption of material and energy, large cylindrical shell rolling is introduced. Large cylindrical shell rolling is a typical rotary forming technology, and the upper and lower rolls have different radii and speeds. To quickly predict the three-dimensional stresses and eliminate fishtail defect, an improved strip layer method is developed, in which the asymmetry of the upper and lower rolls, non-uniform deformation and stress, as well as the asymmetrical spread on the end surface are considered. The deformation zone is divided into a certain number of layers and strips along the thickness and width, respectively. The transverse displacement model is constructed by polynomial function, in order to increase the computation speed greatly. From the metal plastic mechanics principle, the three-dimensional stress models are established. The genetic algorithm is used for optimization calculation in an industrial experiment example. The results show that the rolling pressure, the normal stresses, the upper and lower friction stress distributions are not similar with those of a general plate rolling. There are two relative maximum values in rolling pressure distribution. The upper and lower longitudinal friction stresses change direction nearby the upper and lower neutral points, respectively. The fishtail profile of spread on the end surface is predicted satisfactorily. The reduction could be helpful to eliminate fishtail defect. The large cylindrical shell rolling example illustrates the calculation results acquired rapidly are good agreements with the finite element simulation and experimental values of previous study. A highly effective and reliable three-dimensional simulation method is proposed for large cylindrical shell rolling and other asymmetrical rolling.
基金financial support of the project from the National Key Research and Development Program of China (No. 2016YFB0301104)the National Natural Science Foundation of China (No. 51771043)
文摘The present study aimed to determine the optimum rolling speed for break-down rolling of as-cast AZ31 B alloy and investigated the friction behavior associated with temperature-and reduction-sensitivity at the roll/plate contact interface. Tensile testing, formability evaluation and microstructural studies relevant to different rolling speeds were performed and finally the optimum operating rolling speed（50.0 ± 0.8 m/min） was obtained. Further, the effects of rolling reduction and initial temperature were assessed on the temperature variation, lateral spread and interfacial friction behavior at optimum rolling speed. The results showed that lower rolling speed（18.0 ± 0.8 m/min） resulted in an incompletely recrystallized structure where twins occupied relatively high volume fraction. Twinning dominated the deformation at rolling speed exceeding the optimum, resulting in the local recrystallization with shear bands and coarse grains. Rolling at 50.0 ± 0.8 m/min could get the best overall tensile properties and rolling formability due to the relatively high recrystallization degree and microstructure uniformity. An inverse method has been developed to determine the interfacial friction coefficient during interaction of AZ31 B alloy with roll surfaces. When rolling at the optimum speed, the interfacial friction coefficient ranged from 0.16 to 0.58, which was strongly positively correlated with the reduction but slightly positively correlated with the initial temperature. Depended on the rolling characteristics, external friction effect coefficient ranged from 1.25 to 2.35 and it exhibited positive correlation with both the initial rolling temperature and rolling reduction.
