3D coupled thermomechanical FE analysis of blank size effects on radial-axial ring rolling

Abstract

Radial-axial ring rolling, which is widely used to manufacture large scale seamless rings, is an advanced but complicated plastic forming technique with multiprocess factors coupling with interactive effects. During the radial-axial ring rolling process, the blank size is a decisive parameter because it influences directly the degree of deformation of the ring and the rolling parameters of the process. In this paper, the blank size design method of the radial-axial ring rolling process is first proposed, then a valid three-dimensional (3D) coupled thermomechanical FE model of the process is explored under ABAQUS software environment. Based on the valid 3D FE model, the blank size effects on radial-axial ring rolling are investigated. The research results provide valuable guidelines for blank size design and optimisation in the actual radial-axial ring rolling production.

Set-up of radial–axial ring-rolling process: Process worksheet and ring geometry expansion prediction

“…The thickness and height of the initial blank are plastically deformed and reduced, at the same time but in opposite sections, resulting in a reduction of the ring section area and consequent enlargement of the ring diameter. Regarding the procedure through which to determine blank dimension, Qian et al [11,12] developed an algorithm for the determination of the dimensions of the blank, but this procedure presents difficulties in the definition of the ratio between final cross section and initial cross section of the ring, which is a fundamental parameter for the determination of the initial annular blank. Moreover Zhou et al [13] investigated the thermo-mechanical coupling in radial-axial ring rolling process regarding strain distribution and temperature.…”

Recent development of ring rolling theory and technique

“…Microstructure evolution during RARR was also tried by FE modelling methods (Yeom et al, 2010;Schwich et al, 2014;Zhu et al, 2014a). Through FE simulation, the deformation behaviour, forming laws and process parameters' effects during RARR were revealed visually (Qian et al, 2013c;Xu et al, 2013;Zhu et al, 2014b;Zhou et al, 2010aZhou et al, , 2011aZhou et al, , 2011bZhou et al, , 2012. Furthermore, to reveal the genetic effects of blank forging to ring rolling, macro-microscopic deformation laws during blank forging and ring rolling process were explored (Qian and Pan, 2013).…”

“…By this technology, the material consumption has been saved by 25% average, and the manufacturing cost has been decreased by 20% average. Source: Qian et al (2013c) In terms of equipment, multifunction rolling mills are developed by improving mechanical structure, electrical and hydraulic system based on traditional radial hot rolling mill. This kind of mills can be used for CRR, radial hot ring rolling and three-roll cross rolling (as shown in Figure 15).…”

Modeling and application of ring stiffness condition for radial-axial ring rolling

“…From the analysis above, it can be seen the maximum allowed guiding force Fg-max is determined by Eq. (22). So the pressure p should satisfy the following condition Therefore, the force applied on the guide roll can be determined by…”

“…Simulations of microstructure evolution during RARR have been also tried [16][17][18]. By FE simulation, deformation behaviors during RARR and effects of technological parameters on RARR process have been revealed systematically [19][20][21][22][23].…”