Conception of a Three Roll Cross Rolling Process of Hollow Rail Axles

Pater, Z.; Tomczak, J.; Bulzak, Tomasz; Wójcik, Łukasz

doi:10.2355/isijinternational.isijint-2020-530

Cited by 10 publications

(7 citation statements)

References 24 publications

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“…In the case of three-roll skew rolling such a test is rotary compression of a disc in a channel [24]. Critical damage values for 42CrMo4 grade steel, determined in the course of the presented test, were shown in study [11]. For 1180 °C the critical damage value equals 3.2 and is significantly greater than the maximum values observed in the analysed rolling process.…”

Section: Obtained Resultsmentioning

confidence: 94%

“…On the basis of the analyses performed [8,9] it was stated that in the case of forming hollow elements tools with smaller spreading angle ad greater forming angle ought to be used. Lately, studies [10,11] indicating the validity of employing three rolls in skew rolling processes of hollow elements. In this type of rolling, deformations of the cross-section of the workpiece is significantly smaller than in the case of two-roll rolling.…”

Section: Introductionmentioning

confidence: 99%

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Conception of Hollow Axles Forming by Skew Rolling with Moving Mandrel

Pater¹,

Walczuk-Gągała²

2021

Adv. Sci. Technol. Res. J.

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The article presents a conception of manufacturing a hollow axle using three skewed rolls moving at the same rotating speed, axially moving chuck and a moving mandrel. The outer shape of the axle is obtained as a result of combining the radial feed of the rolls with axial feed of the chuck. The hole in the axle, however, is obtained as a result of the mandrel acting on the workpiece while moving along with it. In order to assess the correctness of the presented concept of forming, a numerical simulation was performed in Simufact. Forming commercial software. The results of the simulation confirmed that the applied method allows one to manufacture large-size hollow axles. Moreover, information on force parameters of the forming process, which can be used for designing an industrial rolling mill was obtained.

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Section: Obtained Resultsmentioning

confidence: 94%

Section: Introductionmentioning

confidence: 99%

Conception of Hollow Axles Forming by Skew Rolling with Moving Mandrel

Pater¹,

Walczuk-Gągała²

2021

Adv. Sci. Technol. Res. J.

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“…In this simulation, the damage function was calculated via the Cockcroft-Latham criterion, which had been employed in previous studies on CWR [20][21][22]. Based on a study conducted by Pater et al [23], it was assumed that the critical value of the damage function causing the fracture of 42CrMo4 steel at 1200 °C was equal to 3.55. An analysis of the damage function distribution in the produced railcar axle shown in Fig.…”

Section: Numerical Analysismentioning

confidence: 99%

Novel Cross Wedge Rolling Method for Producing Railcar Axles

Pater

Tomczak²,

Bulzak³

2023

Preprint

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Railcar axles are large-size parts produced in large batches. Nowadays they are manufactured from semi-finished products obtained by press or rotary forging. Studies are conducted on developing more effective methods for producing these parts, with a focus on methods based on rolling processes. A promising line of research in this respect is connected with the use of cross wedge rolling (CWR), a manufacturing method for producing automotive shafts and axles. Nonetheless, there exist no rolling mills that would make it possible to manufacture such large-size parts as railcar axles. A solution to this problem was inspired by the symmetric shape of a railcar axle, which makes it possible to roll this part in two passes using the same tools. The present paper describes this method of manufacturing railcar axles, which was developed at the Lublin University of Technology. Taking advantage of the potential offered by numerical modelling, simulations were made of two rolling processes for producing a railcar axle type BA302, i.e. one process was conducted with the use of two rolls and the other with two flat tools moving in the opposite directions. It was assumed that the rolling processes would be performed on the largest available rolling mills used for CWR. Numerical results demonstrated that railcar axles produced by the proposed rolling process had neither external nor internal (cracks) defects. The effectiveness of the developed CWR method was ultimately confirmed by the high quality of railcar axles that were produced (in a scale of 1:5) under industrial conditions at the Lublin University of Technology.

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“…In this process the workpiece was deformed into the desired shape during two revolutions of three coupled rolls. Three-roll CWR also became a basis for developing new methods for manufacturing hollow parts, including cross wedge rolling by means of one flat wedge and two shaped rolls [17], rotary compression with the use of rolls [18,19], and three-roll rolling with eccentrically mounted tool segments [20].…”

Section: Introductionmentioning

confidence: 99%

A Comparison of Two-Roll and Three-Roll Cross Wedge Rolling Processes

Pater¹

2023

Adv. Sci. Technol. Res. J.

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Cross wedge rolling (CWR) is used for producing stepped axles and shafts as well as die forging preforms. In current industrial practice, CWR conducted with two tools is predominantly used, with the wedges mounted on rolls or flat tool plates. However, CWR can also be performed with the use of three wedge rolls. This paper begins with a review of previous studies on CWR conducted with the use of three rolls. After that, numerical simulations of two-and three-roll CWR processes for the same shaft are described. Obtained numerical results are then used to compare the two processes in terms of material flow kinematics, material temperature, stresses and strains, failure modes, as well as load and energy parameters. Finally, the Conclusions section presents the advantages of threeroll cross wedge rolling, providing a good starting point for further research on this promising forming method.

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Conception of a Three Roll Cross Rolling Process of Hollow Rail Axles

Cited by 10 publications

References 24 publications

Conception of Hollow Axles Forming by Skew Rolling with Moving Mandrel

Conception of Hollow Axles Forming by Skew Rolling with Moving Mandrel

Novel Cross Wedge Rolling Method for Producing Railcar Axles

A Comparison of Two-Roll and Three-Roll Cross Wedge Rolling Processes

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