Cross-wedge rolling of a 4Cr9Si2 hollow valve: explorative experiment and finite element simulation

Ji, Hongchao; Liu, Jinping; Wang, Baoyu; Zheng, Zhenhua; Huang, Jian; Zheng-huan, HU

doi:10.1007/s00170-014-6363-9

Cited by 51 publications

(12 citation statements)

References 18 publications

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“…square, oval, hexagonal), formed by tools with specially profiled forming surfaces [7][8][9]. The rolling of such parts is characterized by oscillatory variations in the forces resulting from cyclic changes in reduction ratio;  CWR for toothed or worm shafts using tailor-made inserts fixed behind the sizing zone of the tools [10][11][12][13][14];  CWR for hollow parts performed with an elongated sizing zone of the tools [3,[15][16][17][18][19][20][21];  CWR for products made of non-ferrous materials such as titanium alloys [22][23][24], aluminum alloys [12], magnesium alloys [25], superalloys based on nickel [26] and copper [27];  multi-wedge rolling in which the workpiece is formed simultaneously by more than one pair of tools. This rolling technique is used in the production of very long axles and shafts (e.g.…”

Section: New Trends In the Cwr Techniquementioning

confidence: 99%

A New Cross Wedge Rolling Process for Producing Rail Axles

Pater

Tomczak

2018

MATEC Web Conf.

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Rail axles are large-size parts produced in large batches. Currently, these parts are produced by metal forming techniques such as rotary forging, open die forging with hydraulic presses and open die hammer forging (minimum ram weight: 3 Mg). Nevertheless, not only are the above methods far from being efficient, they also lack accuracy (open die forging). As a result, new techniques for producing rail axles are constantly developed. One of such alternative techniques is based on the use of cross wedge rolling (CWR), which is the subject of the present study. An innovative roll design for producing rail axles by CWR is proposed. The rolls are provided with three pairs of wedge tools that act simultaneously on the workpiece and form the part in one revolution of the rolls, i.e., during 20 s. The numerical modelling of a CWR process with the proposed roll design reveals that the solution can be used to produce railway axles with the desired geometry. This technique, however, requires relatively high loads and torques. To decrease the force parameters, the forming process was modified and ran in two operations. The first operation consists in forming the central step of the workpiece while the other one involves the formation of steps on the ends of the workpiece. The results of the new simulation show a significant decrease in the loads and torques, which is caused, among others, by reducing the nominal diameter of the rolls from 1600 mm to 1200 mm. The numerical findings can be used to design a rolling mill for producing rail axles.

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Section: New Trends In the Cwr Techniquementioning

confidence: 99%

A New Cross Wedge Rolling Process for Producing Rail Axles

Pater

Tomczak

2018

MATEC Web Conf.

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“…CWR is usually applied in the metal forming industry for the manufacture of elongated products, such as stepped shafts [6][7][8][9], balls [10], and preforms of forging [11][12][13][14][15][16][17].…”

Section: Working Principle Of Cross Wedge Rollingmentioning

confidence: 99%

Research and industrialization of near-net rolling technology used in shaft parts

2018

Self Cite

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Shaft part rolling is an efficient and green nearnet shaping technology offering many advantages, including high production efficiency, high material utilization rate, high product quality, and excellent production environment. In this paper, the features of shaft part rolling are introduced along with the working principles of two main shaft part rolling technologies, namely, cross wedge rolling (CWR) and skew rolling (SR). In relation to this technology, some R&D achievements gained by the University of Science and Technology Beijing are summarized. Finally, the latest developments in shaft part rolling are presented, including SR steel balls, precise forming of camshaft blank by CWR, SR phosphorous copper balls at room temperature, and CWR hollow axle sleeve. Although the shaft part rolling technology has been widely used in China, it only accounts for about 15% of applicable parts at present. Nevertheless, this technology has broad application prospects.

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“…Figure 5 shows the finite element model, which is composed of two rollers, two guides, and one billet. According to the characteristics of Ti-6Al-4V the titanium alloy CWR, the following assumptions were made to improve the working efficiency of the model: The thermal deformation constitutive equation of the Ti-6Al-4V, obtained by the thermal simulation experiment was imported into Deform-3D [7,20,21,25], and a finite element model of engine blade forming by CWR was established. Figure 5 shows the finite element model, which is composed of two rollers, two guides, and one billet.…”

Section: Establishment Of a Finite Element Modelmentioning

confidence: 99%

Numerical and Experimental Study on the Thermodynamic Coupling of Ti-6Al-4V Blade Preforms by Cross Wedge Rolling

Dong

Xin

et al. 2018

Metals

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Titanium alloy possesses high strength, good corrosion resistance, and high heat resistance; thus, it is widely used in the aerospace and other fields. Blades of titanium alloy are important components of aero-engines and are essential to the engines operation. In this work, a Ti-6Al-4V blade was formed by cross wedge rolling (CWR) to realize the near net-shape of an aero-engine blade. First, thermal simulation experiments of Ti-6Al-4V were carried out to obtain the thermal deformation constitutive equation of the alloy. The finite element software Deform-3D was then used to simulate the thermodynamic coupling of the forming process, and the metal flow, temperature, and stress–strain distribution laws during the forming process were analyzed. Finally, experimental verification of the Ti-6Al-4V blade was carried out by using an H500 CWR mill. The results revealed the feasibility of applying CWR to preform Ti-6Al-4V blades.

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Cross-wedge rolling of a 4Cr9Si2 hollow valve: explorative experiment and finite element simulation

Cited by 51 publications

References 18 publications

A New Cross Wedge Rolling Process for Producing Rail Axles

A New Cross Wedge Rolling Process for Producing Rail Axles

Research and industrialization of near-net rolling technology used in shaft parts

Numerical and Experimental Study on the Thermodynamic Coupling of Ti-6Al-4V Blade Preforms by Cross Wedge Rolling

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