Complex Numerical Analysis of the Tube Forming Process Using Diescher Mill

Abstract

This paper presents the results of FEM simulations of the rotary piercing process in which disc guiding devices of the Diescher type are used. During this process the material is formed by means of two skew rolls, two guiding devices, and the piercing plug mounted on the mandrel. The aim of the analysis was to determine the effect of the plug diameter, the plug advance, the feed angle and the diameter reduction on the piercing process. Nine cases of piercing with three different plugs used were analyzed. The effects of the basic process parameters on the tube shell diameter and the tool load were analyzed. The numerical results obtained using Simufact.Forming 10.0 were verified under experimental conditions in which the tube shell made from 100Cr6 bearing steel was pierced. The results of the FEM calculations show agreement with the experimental results.Keywords: tube piercing, Diescher mill, FEM analysis, experiment W artykule zaprezentowano wyniki symulacji numerycznych procesu dziurowania tulei w walcarce skośnej z prowadnicami tarczowymi Dieschera. W procesie tym materiał jest kształtowany w wyniku oddziaływania dwóch ustawionych skośnie walców, dwóch prowadnic oraz główki dziurującej montowanej na trzpieniu. Celem analizy było określenie wpływu średnicy główki, wysunięcia główki, kąta zukosowania walców oraz gniotu na przebieg procesu dziurowania. Przeanalizowano dziewięć przypadków kształtowania, w których wykorzystano trzy rożne główki dziurujące. Określono wpływ podstawowych parametrów procesu na średnicę tulei kształtowanej oraz obciążenie poszczególnych narzędzi. Wyniki symulacji numerycznej otrzymanej w programie Simufact.Forming 10 zweryfikowano w warunkach doświadczalnych, w których dziurowano tuleje ze stali łożyskowej w gatunku 100Cr6. Rezultaty obliczeń MES pozostawały w dobrej zgodności z wynikami uzyskanymi z doświadczeń.

Rotary compression in tool cavity—a new ductile fracture calibration test

“…To determine the critical damage value with the proposed rotary compression in cavity test, this process must be numerically modelled by the finite element method. The present analysis is performed with the use of the Simufact.Forming simulation software which was effectively used in previous studies into processes such as cross wedge rolling [43][44][45], Mannesmann piercing [30,46,47], helical rolling of balls [48][49][50], three-roll skew rolling [35,51,52] and other rolling processes [53][54][55][56][57]. performed under laboratory conditions.…”

Comparative Analysis of Tube Piercing Processes in the Two-Roll and Three-Roll Mills

“…Later on, the model of the piercing process conducted in Diescher mill, researched by Pater et al was used to determine the influence of the basic parameters of the process on the process itself. Results of the research were published in specialist literature [14,15]. Similar calculations were made by Zhao and Mao [16], who researched the influence of the feed angle of the rolls (in the range 8°÷16°) on the piercing process.…”

FEM Analysis of the Multi-Wedge Helical Rolling Process for a Workholding Bolt

“…In addition, the computations were limited either to the steady-state stage of the process or to the beginning of the forming process. Complete numerical models of the piercing process for thick-walled tubes taking into consideration thermal phenomena were constructed by several authors only in the last ten years [17][18][19][20][21][22][23][24][25]. The computations were performed with commercial simulation programs such as MSC.…”