Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂ca...Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂casting-rolling compound forming technology＂ is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.展开更多
The vee-ring is one of the most characteristic features of the fine-blanking process which is derived from the conventional blanking. With the vee-ring, a counter plate and some other working parameters, a component w...The vee-ring is one of the most characteristic features of the fine-blanking process which is derived from the conventional blanking. With the vee-ring, a counter plate and some other working parameters, a component with a precise geometry and smoothly blanked surface can be produced without any major secondary operations. However, these working parameters are always empirically determined or determined by trial-and-error method, which is time-consuming and expensive. In this study, a numerical simulation method was used to analyze the effect of vee-ring factors on product quality, such as distance between vee-ring and punch, vee-ring height and blank holder force, so as to obtain as high clean cut ratio as possible. During the simulation, the model was assumed as axisymmetric one and the workpiece was considered as rigid plastic material, meanwhile the tools were defined as rigid bodies so as to shorten the computational time. A damage model taking into account the influence of hydrostatic stress was used to simulate material fracture in fine-blanking. The result obtained from the simulation indicated that with the help of vee-ring, the metal material near the shear band does not flow with the punch penetration and high compressive stress in the shear band is generated. Consequently, higher clean cut ratio can be obtained with a vee-ring model than the one obtained with a plane blank holder model. Furthermore, the longer the distance between vee-ring and punch is, the higher the height of roll-over becomes.展开更多
Aiming at solving the difficulties of deforming manufacture of the automobile rear axle bevel gear blank,the paper presented to adopt the numerical simulation method to study the rolling process of the bevel gear blan...Aiming at solving the difficulties of deforming manufacture of the automobile rear axle bevel gear blank,the paper presented to adopt the numerical simulation method to study the rolling process of the bevel gear blank instead of the traditional expensive trail-and-error method. A three-dimensional simulation model of the Φ500 bevel gear blank radial ring rolling machine was firstly created based on the general dynamic explicit finite element code ANSYS/LS-DYNA,and then realized the virtual simulation of the entire rolling process of the bevel gear blank within a producing cycle. The simulation results displayed the real-time blank enlarging and fleck generating as well as the stress,strain and displacement contours,which are in good agreements with the real ring rolling process. It is concluded that this numerical simulation method is feasible and can be used to guide the practical rolling process of the bevel gear blank as well as other profile-shaped annular blanks.展开更多
基金supported by Key Program of National Natural Science Foundation of China(Grant No.51135007)National Natural Science Foundation of China(Grant No.51075290)
文摘Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂casting-rolling compound forming technology＂ is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.
基金The National Natural Science Foundation of China(No50505027)
文摘The vee-ring is one of the most characteristic features of the fine-blanking process which is derived from the conventional blanking. With the vee-ring, a counter plate and some other working parameters, a component with a precise geometry and smoothly blanked surface can be produced without any major secondary operations. However, these working parameters are always empirically determined or determined by trial-and-error method, which is time-consuming and expensive. In this study, a numerical simulation method was used to analyze the effect of vee-ring factors on product quality, such as distance between vee-ring and punch, vee-ring height and blank holder force, so as to obtain as high clean cut ratio as possible. During the simulation, the model was assumed as axisymmetric one and the workpiece was considered as rigid plastic material, meanwhile the tools were defined as rigid bodies so as to shorten the computational time. A damage model taking into account the influence of hydrostatic stress was used to simulate material fracture in fine-blanking. The result obtained from the simulation indicated that with the help of vee-ring, the metal material near the shear band does not flow with the punch penetration and high compressive stress in the shear band is generated. Consequently, higher clean cut ratio can be obtained with a vee-ring model than the one obtained with a plane blank holder model. Furthermore, the longer the distance between vee-ring and punch is, the higher the height of roll-over becomes.
文摘Aiming at solving the difficulties of deforming manufacture of the automobile rear axle bevel gear blank,the paper presented to adopt the numerical simulation method to study the rolling process of the bevel gear blank instead of the traditional expensive trail-and-error method. A three-dimensional simulation model of the Φ500 bevel gear blank radial ring rolling machine was firstly created based on the general dynamic explicit finite element code ANSYS/LS-DYNA,and then realized the virtual simulation of the entire rolling process of the bevel gear blank within a producing cycle. The simulation results displayed the real-time blank enlarging and fleck generating as well as the stress,strain and displacement contours,which are in good agreements with the real ring rolling process. It is concluded that this numerical simulation method is feasible and can be used to guide the practical rolling process of the bevel gear blank as well as other profile-shaped annular blanks.
