Measurement and control of variable geometry during ring rolling

Arthington, Matthew R.; Cleaver, Christopher J.; Allwood, Julian M.; Duncan, Stephen R.

doi:10.1109/cca.2015.7320815

Cited by 10 publications

(5 citation statements)

References 12 publications

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“…Past work has demonstrated that variable thickness rings with uniform curvature [4] and variable curvature rings with uniform thickness [5] can be created using conventional RARR hardware and the additional sensing described earlier. This paper has covered the theory behind the implementation of the control strategy in more depth for these two processes.…”

Section: Test Resultsmentioning

confidence: 99%

“…The use of a camera measurement system in this work enables the control of ring curvature and radial thickness along its circumference. Recent developments in sensing in ring rolling using photogrammetry have shown that it is a practical observation technique [4,6,15,16]. [6] showed that the function of the guide rolls could be replaced by controlling the relative driving speeds of the axial and forming rolls to keep the ring centred.…”

Section: Introductionmentioning

confidence: 99%

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Control of ring rolling with variable thickness and curvature

2019

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Radial-Axial Ring Rolling (RARR) is an industrial forging process for making strong, seamless metal rings. Conventionally, rings are made circular with constant cross-section. In this work we demonstrate a sensing and control strategy to create rings with variable radial wall thickness and variable curvature using standard RARR hardware. This has a number of potentially useful applications but also provides an understanding of how to control these properties for conventional RARR. The sensing uses a calibrated video camera to take a series of images of the ring top surface. Image processing is employed to measure and track the ring material in-situ. The complete state of the ring is represented by the ring thickness and curvature as a function of its volume fraction, which is computed by combining the measurements from the unoccluded areas with estimates of the ring shape elsewhere. Additionally, we present a marking technique for tracking of material as it rotates through the rolling machine, even after significant deformation of the ring has occurred. We show that rings with a wide range of variation in local thickness and curvature can be formed using conventional RARR hardware and a photogrammetric state measurement technique, combined with open-loop scheduling and feedback control of thickness and curvature. Rings with both variable thickness and non-circular shapes have been produced virtually using numerical simulations and in reality using modelling clay as a material to simulate metals at forging temperatures. We demonstrate that this technique extends the range of shapes achievable with standard RARR hardware.

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Section: Test Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Control of ring rolling with variable thickness and curvature

2019

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“…A theoretical basis and reliable control method of the guide roll based on the ring stiffness condition have been proposed [59,60]. Based on the rolling deformation condition and technological requirements, the advanced measurement technique and closed-loop control system were used to reasonably match and control motion parameters of the rolls, which could ensure the realization of automatic rolling [61].…”

Section: Radial-axial Ring Rolling (Rarr)mentioning

confidence: 99%

Developments and perspectives on the precision forming processes for ultra-large size integrated components

Yuan

Fan

2019

Int. J. Extrem. Manuf.

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In order to meet the requirements of high reliability, long-lifetime and lightweight in a new generation of aerospace, aviation, high-speed train, and energy power equipment, integrated components are urgently needed to replace traditional multi-piece, welded components. The applications of integrated components involve in a series of large-size, complex-shaped, high-performance components made of difficult-to-deform materials, which present a huge challenge for forming ultra-large size integrated components. In this paper, the developments and perspectives of several extreme forming technologies are reviewed, including the sheet hydroforming of ultra-large curved components, dieless hydroforming of ellipsoidal shells, radial-axial ring rolling of rings, in situ manufacturing process of flanges, and local isothermal forging of titanium alloy components. The principle and processes for controlling deformation are briefly illustrated. The forming of typical ultra-large size integrated components and industrial applications are introduced, such as the high strength aluminum alloy, 3 m in diameter, integrated tank dome first formed by using a sheet blank with a thickness the same as the final component, and a 16 m diameter, integrated steel ring rolled by using a single billet. The trends for extreme forming of ultra-large size integrated components are discussed with a goal of providing ideas and fundamental guidance for the further development of new forming processes for extreme-size integrated components in the future.

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“…First, the guide rolls were not used, and the ring was centered due to differential velocity control of the axial roll. The current state of the ring geometry was measured by tracking marks on the top of the ring using a USB webcam [11]. Furthermore, the mandrel and main roll were moved together along the X-axis to keep the ring in the center of the rolling mill [9].…”

Section: Introductionmentioning

confidence: 99%

Rolling Eccentric Steel Rings on an Industrial Radial–Axial Ring Rolling Mill

Gröper,

Quadfasel,

Bailly

et al. 2024

JMMP

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Various industries, including mechanical engineering, utilize steel rings featuring variable cross-sectional profiles, such as eccentric rings. Presently employed methods for producing eccentric rings possess drawbacks like restricted geometries, significant material wastage or uneven microstructures. The radial–axial ring rolling process serves to create seamless rolled steel rings with near-net-shaped cross-sections. A novel technique involves achieving eccentricity by dynamically adjusting the mandrel’s position during the ring rolling process. This method’s fundamental feasibility has previously been showcased using a blend of oil clay and a labor test bench. Transferring the possibility of manufacturing eccentric rings on industrial radial–axial ring rolling mills would expand the product range of ring manufacturers without encountering drawbacks associated with existing manufacturing processes. The objective of this paper is to demonstrate the basic feasibility of the concept of an industrial radial–axial ring rolling mill. In the first step, FEA simulation studies were carried out to develop the rolling strategy and estimate the achievable eccentricity on the institute’s radial–axial ring mill. Subsequently, the rolling strategy was implemented on an industrial ring rolling mill with the help of a unique technology module programmed in C++. Finally, an eccentric ring was ring rolled and compared with the FEA simulation, and the reproducibility was demonstrated to be successful.

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Measurement and control of variable geometry during ring rolling

Cited by 10 publications

References 12 publications

Control of ring rolling with variable thickness and curvature

Control of ring rolling with variable thickness and curvature

Developments and perspectives on the precision forming processes for ultra-large size integrated components

Rolling Eccentric Steel Rings on an Industrial Radial–Axial Ring Rolling Mill

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