Influence of Material Properties and Forming Velocity on the Interfacial Slip Characteristics of Cross Wedge Rolling

Friction stir welding is a refreshing approach to the joining of metals. Although originally intended for aluminium alloys, reach of FSW has now extended to a variety of materials including steels and polymers. This review deals with the fundamental understanding of the process and its metallurgical consequences. The focus is on heat generation, heat transfer and plastic flow during welding, elements of tool design, understanding defect formation and the structure and properties of the welded materials.

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“…The extent of slip can be estimated by curve fitting the measured values at various relative velocities [50]:…”

Section: Principles Of Heat Transfer and Materials Flowmentioning

confidence: 99%

Recent advances in friction-stir welding – Process, weldment structure and properties

Nandan

DebRoy

Bhadeshia

2008

Progress in Materials Science

1,820

911

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“…They also modified the relationship derived from the data in the work of Deng et al [22] in cross-wedge rolling to develop the following relationship for the slip as a function of tool radius and welding parameters:…”

Section: Stick Behaviourmentioning

confidence: 99%

A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries

2015

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The tool is a key component in the friction stir welding (FSW) process, but the tool degrades and changes shape during use, however, only a limited number of experimental studies have been undertaken in order to understand the effect that worn tool geometry has on the material flow and resultant weld quality. In this study, a validated model of the FSW process is generated using the CFD software FLUENT, with this model then being used to assess the detail of the differences in the flow behaviour, mechanically affected zone (MAZ) size and strain rate distribution around the tool for both unworn and worn tool geometries. Comparisons are made at two different tool rotational speeds using a single weld traverse speed. The study shows that there are significant differences in the flow behaviour around and under the tool when the tool is worn. This modelling approach can therefore be used to improve understanding of the effective limits of tool life for welding, with a specific outcome of being able to predict and interpret the behaviour when using specific weld parameters and component geometry without the need for experimental trials.

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“…Cross wedge rolling is also widely used for forming billets for the die forging of elongated parts. In addition, the CWR technique can be employed to produce such parts as toothed shafts, screw spikes and balls [3][4][5][6]. In the past, some research was undertaken to investigate the application of CWR for producing twist drills [7].…”

Section: Introductionmentioning

confidence: 99%

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

Tofil¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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The paper presents a selection of numerical and theoretical results of the cross wedge rolling process for producing stepped shafts made of aluminum alloy 6061. The numerical modeling was performed using the FEM-based Simufact Forming simulation software. In the simulations, we examined the kinematics of metal flow and determined the distribution patterns of effective strains, temperatures, axial stresses and the Cockroft-Latham damage criterion. Variations in the rolling forces were determined, too. The numerical results were verified experimentally using a universal rolling mill designed and constructed by the present authors. This machine can be used to perform such processes as cross wedge rolling, longitudinal rolling and round bar cropping. During the experiments, we examined process stability and finished product geometry and recorded the torques. The experimental results confirm that axisymmetric aluminum alloy shafts can be produced by cross wedge rolling with two rolls. Last but not least, the experiments served to evaluate the technological potential of the rolling mill used.Keywords: cross wedge rolling, aluminum alloys, FEM, experiment W pracy przedstawiono wybrane wyniki badań teoretyczno -doświadczalnych procesu walcowania poprzeczno -klinowego odkuwki wałka stopniowanego ze stopu aluminium w gatunku 6061. Analizę teoretyczną przeprowadzono w programie Simufact Forming, bazującym na metodzie elementów skończonych. W trakcie symulacji analizowano kinematykę płynięcia materiału, wyznaczono rozkłady intensywności odkształcenia, temperatury, naprężeń w kierunku osiowym oraz kryterium zniszczenia wg Cockrofta Lathama. Ponadto określono parametry siłowe podczas walcowania. Weryfikacji doświadczalnej wyników modelowania numerycznego procesu walcowania dokonano w uniwersalnej walcarce kuźniczej, która stanowi własna konstrukcję. Zastosowana walcarka umożliwia realizacje takich procesów jak: walcowanie poprzeczno-klinowe, walcowanie kuźnicze wzdłużne oraz dzielenie bezodpadowe. Podczas eksperymentu analizowano stabilność procesu, geometrie ukształ-towanych odkuwek oraz rejestrowano wartość momentów obrotowych. Uzyskane wyniki prowadzonych badań potwierdziły możliwość kształtowania osiowosymetrycznych odkuwek ze stopów aluminium metodą WPK dwoma walcami. W trakcie eksperymentu określono również możliwości technologiczne walcarki.

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Influence of Material Properties and Forming Velocity on the Interfacial Slip Characteristics of Cross Wedge Rolling

Cited by 38 publications

References 7 publications

Recent advances in friction-stir welding – Process, weldment structure and properties

Recent advances in friction-stir welding – Process, weldment structure and properties

A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries

Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

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