Finite Element Analysis of Axial Feed Bar Rolling

Xu, Chunguo; Liu, G.H.; Ren, Guang; Shen, Zhifu; Ma, Chenglong; Ren, Weiwei

doi:10.1016/s1006-7191(08)60011-3

Cited by 9 publications

(3 citation statements)

References 1 publication

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“…Under the action of hydraulic pressure and profiling plate, the axial feeding movements of the rollers are controlled and the billet can be precisely rolled. Besides, Greifzu G proposed the axial feed bar rolling (AVQ) process in 1986, which have two conical rollers arranged in parallel which can rotate circumferentially and feed axially and has been reviewed by Thomas ficker and André hardtmann [3,4]. Recently, skew rolling technology has attracted extensive attention, on the basis of copy skew rolling process, Pater and Shu put forward a three-roller CNC skew rolling process, which realizes precise skew rolling by controlling the movements of roller and billet through advanced CNC system [5], and their experimental study shows that CNC skew rolling can refine the LZ50 grain size from the 150 μm to 30 μm [6].…”

Section: Introductionmentioning

confidence: 99%

An application exploration of flexible skew rolling a rail car axle

Lin

Wang

Liu

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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This paper presents a new method in axles manufacturing called flexible skew rolling (FSR) process and its application exploration was conducted in laboratory by producing a rail car axle. The FSR rolling path for rail car axle was designed and calculated and then programmed into the FSR mill. The material of the rolled shafts was LZ50 steel and its diameter is 60 mm. By conducting experiments, a rail car axle with multistep was rolled successfully. There is no central crack in the rolled piece, and the outer grain is refined into 22.23μm from 76.45μm and the inner grain is refined into 38.94 μm from 83.47 μm. This study results verified that the FSR process is positive and the rail car axle can be rolled by FSR process.

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Section: Introductionmentioning

confidence: 99%

An application exploration of flexible skew rolling a rail car axle

Lin

Wang

Liu

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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“…In order to achieve flexible manufacturing, a process of axial feed rolling was early proposed and investigated [13,14], whose schematic diagram is shown in Fig. 1a.…”

Section: Introductionmentioning

confidence: 99%

Manufacturing large shafts by a novel flexible skew rolling process

Lin

Wang

Zhou

et al. 2021

Int J Adv Manuf Technol

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When manufacturing large shafts with multi-specification and small-batch production, both the conventional forging and rolling process bring a high tooling cost due to heavy forging press or large-size specialized roller. In this study, a novel flexible skew rolling (FSR) process is proposed by adding degrees of freedom to the rollers as compared to the typical skew rolling process. Since each of the FSR rollers has three 34 degrees of freedom (circle rotating, radial rotating and radial feeding), the FSR process 35 can be divided into four stages: radial rolling, rollers inclining, skew rolling and rollers 36 levelling. Therefore, the FSR process can produce various shafts with same rollers via programming different movements. To verify the feasibility of FSR process, a physical investigation corresponding with a numerical simulation for a single-step shaft is undertaken with a Φ80×390 mm C45 steel billet. According to the results from physical experiments and numerical simulations, the FSR formed shaft has a maximum deviation of 0.99 mm, and its microstructure and properties have been improved obviously. Moreover, although there is a tendency of center crack in FSR products as predicted by numerical results, both the transverse and longitudinal section of the physical shaft are free from central cracking. The major forming defects existed on the rolled shaft are knurled pockmarks, surface threads and side cavity, which are the typical defects of the conventional skew rolling and cross-wedge rolling and can be removed by machining. To the authors' knowledge, this novel process has a good combination of flexible production and less loading, which will be of great engineering significance to reduce the tooling cost in large shafts manufacturing.

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“…In the present in order to improve the precision and efficiency of groove design, finite element method has been used more and more widely in metal plastic working field, and gradually become effective method in the rolling process of scientific prediction, process optimization and quantitative control Xu et al [8] analysed the rolled piece shape size, temperature field, strain field and stress field in the bar rolling process on any position and anytime through finite element method, Mei et al [9] by using finite element method analyzed the temperature distribution between hot strip and roller in different conditions, Wang et al [10] combined finite element method with physical metallurgy which not only can predict the temperature, strain and stress distribution, but also can forecast the law of X. T. LI ET AL. 68 microstructure evolution in the process of metal forming that solved the problems in industrial production, Inoue et al [11] used numerical simulation to design groove system, to calculate the strain and temperature distribution of bar rolling process, and then observed microstructure by practical rolling which agreed with simulation results. The trend of new groove and new technology is to get large strain of cross section by technology of improvement and innovation of groove design, and realize ultra-fine grain organization, especially to design new groove by numerical simulation and test and verify by experiments.…”

Section: Introductionmentioning

confidence: 99%

Groove Design and Microstructure Research of Ultra-Fine Grain Bar Rolling

Li¹,

Cao²,

Wang³

et al. 2012

MNSMS

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New flat-oval groove rolling process of multi-direction deformation is proposed to manufacture ultra-fine grain bar. Application of new groove series can introduce uniform large plastic strain into whole cross section of the material, and meanwhile satisfy the requirements of shape and size. Principle of grain refinement, based on experimental research of small specimen, is that grain refinement of ferrite is mainly dynamic recrystallization when low-carbon alloy steel is at low temperature deformation. Relationship of grain size and z-factor is also obtained through experimental research, as well as ultra-fine ferrite grain less than 1 micron. To predict strain, shape, dimensions and grain size of the material in rolling process, numerical simulation model of the warm groove bar rolling process is established via nonlinear finite element method, and distribution of grain size of the final section is obtained via finite element subroutine. The result indicates that ultra-fine grain bar rolling can accomplish at low temperature region.

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Finite Element Analysis of Axial Feed Bar Rolling

Cited by 9 publications

References 1 publication

An application exploration of flexible skew rolling a rail car axle

An application exploration of flexible skew rolling a rail car axle

Manufacturing large shafts by a novel flexible skew rolling process

Groove Design and Microstructure Research of Ultra-Fine Grain Bar Rolling

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