Three Dimension Rigid-plastic Finite Element Simulation for Two-Roll Cross-wedge Rolling Process

Cross-wedge rolling (CWR) is a metal process of ro ta ry forming. To produce a part, one cylindrical billet should be placed between t wo counterrotating and wedge-shape dies, which move tangentially relative each other. The billet suffers plastic deformation (essentially, localized compressio n) during its rotation between the rotating dies. Compared to other numerical si mulation methods, the finite element method (FEM) has advantages in solving gene ral problems with complex shapes of the formed parts. In cross-wedge rolling, t here are four stages in the workpiece deformation process, namely knifing, guidi ng, stretching and sizing stage. It is time-consuming and expensive to design t he CWR process by trial and error method. The application of numerical simul ation for the CWR process will help engineers to efficiently improve the process development. Tselikov, Hayama, Jain and Kobayashi, and Higashimo applied the sl ip-line theory in study of CWR process analysis. Zb.pater studied CWR process i ncluding upsetting by upper-bound method. The above numerical simulation were b ased on the two-dimensional plain-strain assumption ignored the metal flow in workpiece axial direction. Therefore, the complex three-dimensional stress and deformation involved in CWR processes were not presented. Compared to other nume rical simulation methods, the finite element method (FEM) has advantages in solv ing general problems with complex shapes of the formed parts. As yet, a few 3-D finite element simulation studies on CWR process have been reported in literatu res. In this paper, the process of cross wedge rolling (CWR) has been simulated and analyzed by 3D rigid-plastic finite element method. Considering the charact eristic of CWR, the static implicit FEM program is selected. The models proposed in this study uses the commercial code DEFORM 3D to simulate the CWR process. T his is an implicit Lagrangian finite element code, which includes many new enhan cements functions. A new method of utilizing multiple processors using the MPI s tandard has been implemented. Automatic switching between the two different defo rmation solvers (Sparse Solver and Conjugate Gradient Solver) has also been impl emented in order to increase the speed of simulations. In this paper, all stages in CWR process are simulated to be able to closely understand and analyze the a ctual CWR process. For simulating all forming stages in CWR process, the dynam ic adaptive remeshing technology for tetrahedral solid elements was applied. T he stress distributions in cross section of forming workpiece are analyzed to in terpret fracture or rarefaction in the center of workpiece. Authors also analyze d the time-torque curve and the laws of load changing.

Effect of cross wedge rolling on the microstructure of GH4169 alloy

The metal microstructure during the hot forming process has a significant effect on the mechanical properties of final products. To study the microstructural evolution of the cross wedge rolling （CWR） process, the microstructural model of GH4169 alloy was programmed into the user subroutine of DEFORM-3D by FORTRAN. Then, a coupled thermo-mechanical and microstructural simulation was performed under different conditions of CWR, such as area reduction, rolling temperature, and roll speed. Comparing experimental data with simulation results, the difference in average grain size is from 11.2% to 33.4% so it is verified that the mierostructural model of GH4169 alloy is reliable and accurate. The fine grain of about 12-15 p.m could be obtained by the CWR process, and the grain distribution is very homogeneous. For the symmetry plane, increasing the area reduction is helpful to refine the grain and the value should be around 61%. Moreover, when the roiling temperature changes from 1000 to 1100℃ and the roll speed from 6 to 10 r.min-1, the grain size of the rolled piece decreases first and then increases. The temperature may be better to choose the value around 1050℃ and the speed less than 10 r-min-1.

The Numerical Simulation on Hollow Part's Precise Sizing Process With Cross-wedge Rolling

The hollow parts formed with cross-wedge rolling (CWR) have a wide application in many fields, such as architecture and automobile, etc. But the finished configuration of part’s cross section was always ellipse and it was hard to make it satisfied with traditional forming process. This paper proposed a FEM model of hollow workpiece of CWR in the sizing process, and simulated the deformation condition using the ANSYS program. Three kinds of parts with different wall thickness were calculated. Some stress and strain fields of the deformed hollow parts at various conditions are gained. The influence of wall thickness on the distribution of stress and strain was analyzed. The paper also found two phenomena, which never have been seen at traditional experiment, and author tried to give some explanations. The ANSYS program provided the relationship between the tolerance of the deformed workpiece and the deforming parameter. It is helpful to design the sizing dies of a new precise forming process of hollow parts on the CWR. The new process that designed through the information of FEM improved the accuracy of hollow parts on CWR. It proved the validity and practicability of numerical simulation.

Finite element analysis and experiment on multi-wedge cross wedge rolling for asymmetric stepped shaft of C45

A rigid-plastic finite element method(FEM) simulation model for a multi-wedge cross wedge rolling(MCWR) was developed to analyze an asymmetric stepped shaft. To evaluate the MCWR process and better understand its deformation characteristics, the material flowing mechanisms, temperature distributions, strain and rolling force were analyzed. The correctness of the finite element simulation is experimentally verified. Numerical simulations and experiments led to the following conclusions: when α=36° and β=7.5°, the quality of the work piece can be significantly improved. Finally, the development of the asymmetric stepped shaft is applied to industrial production.

Influence of process parameters on the microstructural evolution of a rear axle tube during cross wedge rolling

In the shaping process of cross wedge rolling（CWR）, metal undergoes a complex microstructural evolution, which affects the quality and mechanical properties of the product. Through secondary development of the DEFORM-3D software, we developed a rigid plastic finite element model for a CWR-processed rear axle tube, coupled with thermomechanical and microstructural aspects of workpieces. Using the developed model, we investigated the microstructural evolution of the CWR process. Also, the influence of numerous parameters, including the initial temperature of workpieces, the roll speed, the forming angle, and the spreading angle, on the grain size and the grain-size uniformity of the rolled workpieces was analyzed. The numerical simulation was verified through rolling and metallographic experiments. Good agreement was obtained between the calculated and experimental results, which demonstrated the reliability of the model constructed in this work.

基于连续损伤力学的楔横轧芯部损伤建模及预测

楔横轧因存在芯部损伤累积行为而容易形成芯部疏松缺陷,准确预测芯部损伤形成条件对楔横轧轴类件高性能制造具有重要意义。开展了不同条件下的热拉伸试验,得到了影响材料损伤的主要因素;基于连续损伤力学,提出了耦合温度、应变速率和应力三轴度的损伤本构模型;开展了不同断面收缩率的楔横轧试验,标定了损伤本构模型的材料断裂阈值,并验证了损伤模型的预测精度;利用该模型预测了断面收缩率、展宽角、成形角对芯部损伤的影响规律,为参数选择提供参考。研究结果表明:温度、应变速率及应力三轴度都显著影响材料损伤行为,所建立的耦合损伤本构模型能较好地预测楔横轧芯部的损伤演化过程;楔横轧芯部损伤与成形角成反比,与展宽角和断面收缩率成正比,各参数影响程度由小到大依次为断面收缩率、展宽角、成形角。

One-way successive plate cross wedge rolling machine

In our last paper(Sci China Ser E-Tech Sci,2009,52(11):3117-3121) we designed the precision forming machine with rolling plate CWR(cross wedge rolling).This kind of machine colligates the advantages of high rigidity and small floor space for roller CWR machine and those of simple die manufacture and high precision for plate CWR machine.At the same time,it abandons the shortcomings of complex die manufacture and poor precision for roller CWR machine,and those of poor rigidity and large floor space for plate CWR machine.During rolling,the upper and lower rolling plates of the machine make reciprocating slide toward or away from each other,so the inertial forces should be overcome,which will cause great energy loss,besides,large floor space is needed when the rolled workpiece is large.In order to solve the above problems,this paper presents the one-way successive plate CWR machine,whose rolling plates need not make reciprocating slide.Hence,it has high energy utilization efficiency and production efficiency.Furthermore,the roll scale can be removed automatically.In particular,the machine can produce large axisymmetrical workpieces.

Analysis of Metal Forming in Two-Roll Cross Wedge Rolling Process Using Finite Element Method

A simulation model for two-roll cross wedge rolling （CWR） was presented by using three-dimensional rigid-plastic finite element method （FEM）. The whole forming process of CWR, including knifing zone, guiding zone, stretching zone, and sizing zone, was simulated using the model in which dynamic adaptive remeshing technology for tetrahedral solid elements was used to fix element distortion. Based on the simulation results, the distributions of metal flow field, strain field, and damage field, and the geometry of the workpiece＇s end were analyzed. These results could provide theoretical guidance for realizing net shaping and reasonable design of tools.

Precision forming machine with rolling plate cross wedge rolling

Roller cross wedge rolling(CWR)machines have high rigidity, but sector dies are difficult to process. Plate CWR machines have low rigidity and need large floor space, but plate dies are easy to process. Neither roller CWR machine nor plate CWR machine can produce larger workpieces. Based on the above conclusions, this paper presents the mechanical principle of the precision forming machine with rolling plate CWR. Then, its design principle and machine construction are presented. There are a top press roller above the upper sliding plate and a bottom press roller under the lower sliding plate. The press rollers make rolling contact with the sliding plates. The plate dies are mounted on the upper and lower sliding plates, respectively. Furthermore, the axes of both press rollers and centerline of work-piece always keep in the identical vertical plane during forming process. These make the machine retain advantages of high rigidity for roller CWR machine and simpleness of manufacturing dies for plate CWR machine, and abandon defects of poor rigidity for plate CWR machine and difficulty of manufac-turing dies for roller CWR machine. Moreover, the machine can produce larger workpieces.

Novel evaluation method for metal workability during cross wedge rolling process

This study presents a novel method using a disk-like sample to assess the workability of metal during the cross wedge rolling(CWR)process.Using this method,we can quantitatively evaluate the moment destruction which occurs at the center of the sample during CWR.In this study,45 steel was selected to demonstrate the proposed method.Firstly,we designed a model for the tools and sample,conducted finite element simulations to analyze the distribution regulations of metal flow,stress,and strain,and evaluated the relationship between the damage and moving distance of the tool during the forming process.Then,we obtained the optimal deformation temperature range,rolling speed,and geometry parameters for the tool.Finally,experiments were conducted from 20℃ to 1200℃ to verify the accuracy of the developed model.It was demonstrated that the model was significantly accurate in accessing the workability of 45 steel in the CWR process.The proposed method could be generalized to investigate the CWR process for other materials,such as aluminum alloys,superalloys,titanium alloys,etc.

Multi-Wedge Cross Rolling of Balls

The multi-wedge cross rolling process of forming balls is described. The process tool for rolling 8 balls with a diameter of 35 mm is presented. The course of the rolling process, distributions of forming forces as well as maps of effective strain and temperature in the obtained balls are presented by finite element modeling （FEM）. Ex- perimental tests of simultaneous forming of 4 balls with a diameter of 22 mm conducted in laboratory conditions at Lublin University of Technology have proved that the balls obtained in multi-wedge cross rolling are of good quality and can therefore be used in both ball mills and rolling bearings.

Cross-Wedge Rolling of Shafts With an Eccentric Step

A new concept for forming eccentric shafts on the basis of the cross-wedge rolling （CWR） process was presented. This concept was based on the application of special guides, which, by acting on a billet, lead to its controlled movement in the vertical direction. This movement made possible eccentric cutting of tools into the billet. FEM calculations and experimental rolling tests clearly confirmed the effectiveness of the proposed forming method.

Effect of tempering on bonding characteristics of cross wedge rolling 42CrMo/Q235 laminated shafts

To further improve the comprehensive properties of 42CrMo/Q235 laminated shafts produced by cross wedge rolling.theheat treatment of the shafts was studied.Tensile and bending tests were carried out to compare the changes in mechanicalproperties before and after heat treatment.The results showed that the interfacial bonding strength increased most aftertempering at 350℃for 45 min.The microstructure of the interface was observed using a digital microscope.The resultsshowed that the dispersed oxides on the interface were basically eliminated by using the scheme of tempering at 350 cand holding for 45 min.The reasons for the change in mechanical properties were explained from the point of theinterfacial microstructure.Scanning electron microscopy was used to analyze the micro-morphology of the tensile fracture.lt was observed that after tempering at 350℃and holding for 45 min,the dimple holes became larger and deeper,and thestructure of fracture became more uniform and stable.From the point of the tensile fracture morphology.the reasons for thechange in mcchanical propcrties wcrc explained as well.

Influence of process parameters on interracial tensile strength of crosswedge rolling of 42CrMo/Q235 laminated shafts

Through rolling experiments and interfacial tensile strength tests of cross-wedge rolled laminated shafts of 42CrMo/Q235 composites, the influence of process parameters, including forming angle, spreading angle, area reduction, rolling temperature and core material diameter on the interfacial shear strength was analyzed. The results show that the sequence of process parameters in order of greatest influence on interfacial tensile strength was rolling temperature, area reduction, core material diameter, forming angle and spreading angle. At the interface of the combined materials, tensile strength decreased as forming angle and spreading angle increased, whereas the tensile strength first increased and then decreased as area reduction, rolling temperature and core material diameter increased.

大型轴类楔横轧机主传动系统模态柔性研究及有限元模拟

针对大型轴类楔横轧机轧制过程中的振动现象,采用弹簧-质量系统动力学模型简化方法,构建了大型轴类楔横轧机的主传动系统的动力学模型,并基于此对扭转振动特性进行了分析,得到了固有频率与主振型。根据系统模态固有特性,分析了系统的各阶模态柔性和能量分布,并利用ANASYS软件构建了有限元动力学分析模块对传动系统进行模态分析,得到系统整体各阶模态固有频率和主振型,振型图中展示了各个阶次的振动特点。为了降低计算复杂度,针对传动轴连接,采用简化模型来模拟复杂的轴结构,但简化模型可能引入误差并无法准确捕捉所有模态。理论系统扭振频率和模态分析结果的扭振频率基本一致。在此次模拟中,简化传动轴连接对分析结果没有显著影响。结果表明,第1阶模态是最敏感、最易被激发的模态,系统能量主要集中在轧辊附近,且容易受到自激振动的影响,后续可以据此可对系统进行进一步研究与优化。

多台阶TC4非对称轴类零件楔横轧成形研究

为实现某TC4非对称轴类件的精密制造,本文中研究楔横轧成形工艺并根据零件特征设计板式楔横轧模具,使用有限元模拟软件进行不同温度下的仿真模拟,分析了轧件在600、800、1000℃三个轧制温度下成形过程的温度、应力-应变以及损伤分布,结果表明:轧制温度1000℃时轧件的成形效果最佳且尺寸精度最高。通过高精度板式楔横轧机进行实验验证,实验与模拟结果吻合,轧件组织沿径向分布存在梯度,并无明显缺陷,达到目标需求。

球头销辊式楔横轧球头成形规律研究

为了研究球头销辊式楔横轧球头的成形规律,利用Deform-3D有限元模拟和点追踪分析得到了球头金属流动和分配规律以及应力、应变曲线。结果表明,通过金属体积分配确定了球头在原始坯料的成形位置,得到了球头金属流动轨迹,其呈周期螺旋线式运动。球头轴向等效应力值先增大后减小最后趋于稳定。当金属在靠近球头成形时,应力值仍然会增加,而到最大值的时间也会延长。球头轴向等效应变值逐渐增大,直到轧制完成,等效应变值达到最大;靠近料头的金属应变速率激增,应变值增大。

基于连续损伤力学模型的楔横轧心部疏松缺陷建模与应用研究

针对楔横轧心部疏松缺陷削弱材料强度,导致工件失效,影响零件的最终寿命的问题,采用一种基于连续损伤力学的耦合损伤模型研究了楔横轧心部疏松产生的规律。首先,通过拉伸实验、循环加载-卸载实验、缺口拉伸实验标定了调质45钢在26和500℃下的本构参数,再建立有限元模型进行仿真,研究了轧制温度、展宽角、断面收缩率和成形角对心部损伤演化的影响。结果表明,较低的轧制温度、较小的成形角、较大的展宽角和断面收缩率易使轧件心部产生疏松缺陷。在模具参数中展宽角、断面收缩率、成形角对心部损伤的影响依次减小。

工艺参数对楔横轧球头销球头成形质量的影响

为了研究球头销微观组织晶粒分布规律以及工艺参数对成形质量的影响,通过DEFORM-3D有限元分析软件建立了楔横轧球头销有限元模型,对球头销成形过程及微观组织变化进行了模拟。结果表明,随着展宽角β的增大,平均晶粒尺寸和最大间隙比先减小后增大,最大间隙比增大到9.25%后逐渐趋于稳定;随着成形角α和楔尖圆角r的增大,平均晶粒尺寸与最大间隙比均先减小后增大;随着轧制温度T的升高,平均晶粒尺寸和最大间隙比逐渐减小,而最大间隙比减小至2.33%后逐渐趋于稳定。通过正交试验设计得到主次影响顺序为:展宽角β、轧制温度T、成形角α和楔尖圆角r;最佳工艺参数组合为:展宽角β=11°、成形角α=29°、轧制温度T=1140℃、楔尖圆角r=9.5°。通过球头销轧制试验得到球头销轧件,测量了其成形尺寸与微观组织晶粒;通过试验与模拟对比,得到外形尺寸误差在5%以内,平均晶粒尺寸最大误差不超过15%,进一步验证了有限元模型的准确性。

楔横轧非对称轴类件有限元模型分析

楔横轧单件轧制非对称轴类件存在轴向力和切向力不平衡问题。在楔横轧非对称轧制中,不平衡轴向力和切向力的测量是解决轧件轴向窜动和轧件扭曲等问题的关键。文章采用DEFORM-3D有限元软件,利用模具分割方法建立的模型得到了不平衡轴向力和切向力。该方法建立的有限元模型,为研究楔横轧各个变形区的成形特征奠定了基础,对进一步研究楔横轧理论具有积极意义。