Computer Simulation of Mannesmann Piercing of Aluminium Alloy Ingots

Skripalenko, M. M.; Романцев, Б. А.; Баженов, В. Е.; Tran, Bach H.; Skripalenko, M. N.; Галкин, С. П.; Savonkin, M. B.; Gladkov, Yu. A.

doi:10.3103/s1067821219010127

Cited by 4 publications

(7 citation statements)

References 14 publications

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“…In practice, however, these types of processes can lead to so-called low-cycle fatigue of material, known as the Mannesmann effect. To see whether the forgings obtained by CWR and HWR had internal cracks produced by the Mannesmann effect [18], the studs were cut along their axis as shown in Figure 8. No internal cracks were observed in either case.…”

Section: Resultsmentioning

confidence: 99%

A Comparative Study of Helical and Cross-Wedge Rolling Processes for Producing Ball Studs

et al. 2019

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This paper presents two rolling technologies: cross-wedge rolling (CWR) and helical-wedge rolling (HWR). The two rolling processes were compared using the example of rolling a ball stud forging. The technologies were modeled in the finite element model (FEM) environment. Calculations were performed to obtain distributions of strain and the Cockcroft–Latham damage criterion. The investigated processes were also performed under real-life conditions. The results of the experiments were used to compare the force and energy parameters of the rolling technologies. Tests were also carried out to investigate the microstructure of the studs and a grain size after rolling. The state of the macrostructure, i.e., the grain flow lines, was also compared. The experiments showed that HWR was a more energy-efficient process.

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Section: Resultsmentioning

confidence: 99%

A Comparative Study of Helical and Cross-Wedge Rolling Processes for Producing Ball Studs

et al. 2019

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“…Ingots of 60 mm diameter and 210 mm height were cast. Before pouring, the mold was covered using Cillolin Al285 coating [ 25 , 26 ]. The AA6060 alloy was used for experiments because it has good technological plasticity.…”

Section: Methodsmentioning

confidence: 99%

“…Regarding the review of two-high screw rolling research publications, it is worth noting articles connected with hollow shell microstructure formation under different deformation regimes [ 20 , 21 , 22 , 23 , 24 ]. Publications [ 25 , 26 ] are about the influence of the shape and dimensions of the plug on the accuracy of the hollow shell dimensions. As a result of a review of the publications, no articles concerning the impact of the shape and dimensions of the plug on the hollow shells’ properties were found.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Hardness of Hollow Tube Shells at Piercing in Two-High Screw Rolling Mill with Different Plugs

et al. 2022

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AA6060 ingots were pierced in a two-high screw rolling mill (MISIS-130D) with guiding shoes (Mannesmann mill type). Three different plugs, i.e., a conventional entire plug, a plug with a cavity, and a hollow plug, were used for piercing. We established that the grain size decreases after piercing, by order of magnitude, compared to the initial non-pierced annealed bill, with a grain size of 100–400 μm, and the hollow shell grains are elongated along the piercing direction. The produced hollow shells had 30% higher hardness than the initial billet. The highest hardness values were obtained after piercing the conventional entire plug. The most uniform hardness distribution through the hollow shell’s volume was obtained after piercing the hollow plug. The cross and longitudinal section hardness measurements demonstrate that the hardness decreases from the outer surface to the inner surface of the hollow shells.

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“…Accepting that fluid is almost incompressible, and viscosity spatial derivatives are minuscule, numerous terms in the tensor viscous stress can be disregarded. In the momentum equation, we apply Galerkin's approach to obtain the following expression previously used in [27]:…”

Section: Discretization For Momentum Equationmentioning

confidence: 99%

Mathematical Modelling for Furnace Design Refining Molten Aluminum

Saldívar

Martínez

Valdés

et al. 2021

Metals

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The design of an aluminium melting furnace has faced two challenges: mathematical modelling and simulative optimization. This paper first uses fluid dynamics to model the aluminium process mathematically. Then, the model is utilized to simulate a round shaped reverberatory furnace for melting aluminium alloys. In order to achieve the highest thermal efficiency of the furnace, modelling and simulation are performed to predict complex flow patterns, geometries, temperature profiles of the mixture-gas air through the main chamber, as well as the melting tower attached to the furnace. The results led to the establishment of optimal position and angle of the burner, which are validated through physical experiments, ensuring recirculation of the combustion gases through the melting chamber and the melting tower. Furthermore, a proper arrangement of refractory materials is derived to avoid heat losses through the outer surface of the furnace. Temperature profiles are also determined for the optimization to arrive at the final design of the furnace. Compared with manual designs previously practiced, the simulation-based optimal design of furnaces offers excellent guidance, an increase in the aluminium processing and magnesium removal for more refined alloys, and an increased processing rate of aluminium chip accession.

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Computer Simulation of Mannesmann Piercing of Aluminium Alloy Ingots

Cited by 4 publications

References 14 publications

A Comparative Study of Helical and Cross-Wedge Rolling Processes for Producing Ball Studs

A Comparative Study of Helical and Cross-Wedge Rolling Processes for Producing Ball Studs

Microstructure and Hardness of Hollow Tube Shells at Piercing in Two-High Screw Rolling Mill with Different Plugs

Mathematical Modelling for Furnace Design Refining Molten Aluminum

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