Investigating Wear and Predicting Lifetime of the Roller Cavities for the Net-shape Blade Rolling

Abstract

The die undergoing severe loads which induces inevitably wear in the pressure forming process, and the wear of die arouses obsessions about the die’s service lifetime. In order to obtain the geometrical shape transformation caused by wear and predict the service lifetime for a pair of rollers in net-shape blade rolling process, this paper quantified the distributions and evolutions of the local wear over roller cavities based on the local contact load responses, and predicted the lifetime which related to wear by a mathematical models. Firstly, the net-shape blade rolling process and the local contact load responses were summarized. Then, an improved wear model was provided based on the Archard formula, and the impact factors of the model was standardized by a regression analysis experiment. The transient wear distributions and evolutions over the roller cavities were enumerated, and the wear distribution for one rolling cycle was calculated based on wear accumulation effect. Finally, a lifetime prediction model was proposed to predict the service lifetime of the rollers according to the wear accumulation effect, and an experimental verification was carried out to validate the model. The results showed that the wear model and lifetime prediction model can be used for investigating the wear and lifetime prediction of the roller cavities for the net-shape blade rolling process.