Finite element analysis and experimental validation of the wedge rolling process

Abstract

A numerical model, developed for LS-Dyna solver, aimed to study the wedge rolling process is presented in this article. In addition, a comparison is made between the experimental and simulated results in order to set up the numerical model’s definition and simulation parameters. The computational performances are evaluated throughout this article to identify the best practice parameters for cold rolling numerical analysis using wedge tools. For an evaluation of the performances of the numerical model, an experimental system was developed to analyse the process parameters of the complex profiles with grooves formed by wedge tools. The methodologies used to record and evaluate the experimental results and the capabilities of the technique are discussed. For a complete analysis, the material behaviour is described by using a five-parameter strain-hardening law. Both the radial force (process force) and the micro-hardness were measured using the Vickers method on a radial section of the rolled piece. The issues addressing the numerical simulation can be extrapolated to other processes (e.g. riveting, flow forming) as this article provides the required information for the development of reliable numerical models.

Fracture simulation of partially threaded bolts under tensile loading

“…Since the machined part in PT bolt specimen locates in unthreaded part of the bolts, the measured engineering stress-strain curves for PT bolts only represent the behaviour of unthreaded part, whereas the measured engineering stress-strain curves for FT bolts represent the behaviour of threaded part. The stressstrain behaviour of threaded part of PT bolts is slightly different from the corresponding unthreaded part, because thread rolling process for producing the external threads of bolts introduces large plastic strain in the threaded region, as analysed in [25][26][27][28]. Effects of thread rolling process on thread failure behaviour will be discussed in the following analysis.…”

The formation mechanism of protrusion of long thread by axial self-infeed rolling process

“…For the external thread forming, Song et al 11 described the deformation process and displayed four kinds of the protrusions in the radial infeed rolling process. Nitu et al 18 analyzed the wedge rolling process through experiments and simulation. Domblesky and Feng 19,20 investigated the external thread formation of the radial infeed rolling process through the finite element model.…”

The importance of forming parameters on rolling process and the performances of component in forming long threads

“…Furthermore, experimental tests were conducted in the laboratory. Nitu et al 15 using simulation and experimental methods studied the radial force and microhardness during the wedge rolling process. Lee et al, 16 Chen et al 17 and Qi et al 18 modeled the thread rolling process and verified the reasonability by experiments.…”

“…Nitu et al. 15 using simulation and experimental methods studied the radial force and microhardness during the wedge rolling process. Lee et al., 16 Chen et al.…”