Numerical and experimental study on the hot cross wedge rolling of Ti-6Al-4V vehicle lower arm preform

Li, Peiai; Wang, Baoyu; Feng, Pengni; Shen, Jinxia; Wang, Jiapeng

doi:10.1007/s00170-021-07979-3

Cited by 8 publications

(3 citation statements)

References 30 publications

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“…Peng et al [ 87 ] analyzed 46 cases of CWR to determine wear characteristics of the wedge tools. Li et al [ 88 , 89 ] investigated the CWR of a vehicle arm preform to determine the optimum temperature of the billet. Feng et al [ 90 , 91 ] investigated the production of a hollow shaft by CWR with a mandrel.…”

Section: Cwr Formation Of Parts Made Of Non-ferrous Materialsmentioning

confidence: 99%

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Pater

2023

Materials

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The aim of this article is to review the application of the finite element method (FEM) to cross-wedge rolling (CWR) modeling. CWR is a manufacturing process which is used to produce stepped axles and shafts as well as forged parts for further processing on forging presses. Although the concept of CWR was developed 140 years ago, it was not used in industry until after World War 2. This was due to the limitations connected with wedge tool design and the high costs of their construction. As a result, until the end of the twentieth century, CWR tools were constructed by rolling mill manufacturers as they employed engineers with the most considerable experience in CWR process design. The situation has only changed recently when FEM became widely used in CWR analysis. A vast number of theoretical studies have been carried out in recent years, and their findings are described in this overview article. This paper describes nine research areas in which FEM is effectively applied, namely: the states of stress and strain; force parameters; failure modes in CWR; material fracture; microstructure modeling; the formation of concavities on the workpiece ends; CWR formation of hollow parts; CWR formation of parts made of non-ferrous materials; and new CWR methods. Finally, to show the potential of FEM on CWR modeling, a CWR process for manufacturing a stepped shaft used in car gearboxes is simulated numerically. This numerical simulation example shows that FEM can be used to model very complex cases of CWR, which should lead to a growing interest in this advanced manufacturing technique in the future.

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Section: Cwr Formation Of Parts Made Of Non-ferrous Materialsmentioning

confidence: 99%

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Pater

2023

Materials

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“…Hu et al [13] incorporated the Arrhenius constitutive model into the commercial nonlinear FE software Abaqus/ Implicit using the UHARD subroutine. Li et al [14] applied the established Arrhenius constitutive to the DEFORM-3D, and simulated the cross wedge rolling process of the TC4 alloy. However, the programs did not account for the compensation of strain, strain rate, and temperature, making them unsuitable for materials that are sensitive to deformation conditions, particularly when large deformations and temperature fluctuations occur, and will result in greater errors.…”

Section: Introductionmentioning

confidence: 99%

A Modified Arrhenius‐Type Constitutive Model and its Implementation by Means of the Safe Version of Newton–Raphson Method

Liang

Kong

Zhang

et al. 2022

steel research int.

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Arrhenius‐type constitutive models are widely used in thermomechanical processing due to their ease of parameter calibration and ability to track the deformation behavior with various materials. Herein, a modified Arrhenius model is proposed, and the model is implemented in the finite element (FE) simulation to improve the simulation accuracy. The VUMAT Fortran subroutine of the model is established for the commercial nonlinear FE software Abaqus/Explicit based on an implicit time integration scheme and the radial return mapping algorithms. A root‐finding method called the safe version of Newton–Raphson method is applied to calculate the plastic corrector term. The efﬁciency and accuracy of both analytical and numerical methods are evaluated for calculating the derivatives in this algorithm. The implementation of the user‐defined modified Arrhenius‐type material model is successfully applied to a thermal–mechanical coupling FE model for the hot rolling of heavy steel plate. The goal optimization function is used to calibrate the material parameters for the model. The plastic strain field and temperature field are in accordance with the theoretical derivation and experimental results. It provides valuable references for characterizing and optimizing thermomechanical processing.

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“…Although the above models have been established and compared, there is still a lack of practical and accurate models to calculate the flow behavior of annealed TA31. It is essential to seek a suitable constitutive model to exhibit high accuracy, which is easy to combine with FEM [23,24].…”

Section: Introductionmentioning

confidence: 99%

The Comparation of Arrhenius-Type and Modified Johnson–Cook Constitutive Models at Elevated Temperature for Annealed TA31 Titanium Alloy

Yang¹,

Liang

Gao³

et al. 2022

Materials

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Constitutive models play a significant role in understanding the deformation behavior of materials and in optimizing the manufacturing process. In order to improve the reliability of calculation results, the high temperature flow behavior of TA31 titanium alloy obtained from an annealed hot-rolled plate has been investigated by a Gleeble-3500 thermo-mechanical simulator. The isothermal hot compression tests are conducted in the temperature range of 850 to 1050 °C and the strain rate range from 0.001 to 10 s−1 with a height reduction of 60%. The annealed TA31 shows a dynamic recovery characteristic during thermo-mechanical processing. The experimental data have been used to develop an Arrhenius-type constitutive model and a modified Johnson–Cook model under the consideration of coupling effect on strain, temperature, and strain rate, as well as the strain-softening phenomenon. The material parameters are determined by a global optimization method based on the initial values by means of a regression method. A comparation of the predicted results has been performed based on the modified Johnson–Cook model and those acquired from the Arrhenius-type model. The correlation coefficient and average absolute relative error of the modified Johnson–Cook model are 4.57% and 0.9945, respectively. However, when the optimization method has been applied, they are 15.77% and 0.9620 for the Arrhenius-type model, respectively. These results indicate that the modified Johnson–Cook model is more accurate and efficient in predicting the flow stress of annealed TA31 titanium alloy under a set of model material parameters. Furthermore, the simple mathematical expression of this model is helpful to incorporate it into the finite element software to obtain detailed and valuable information during the thermo-mechanical processing simulation for TA31 in further work.

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Numerical and experimental study on the hot cross wedge rolling of Ti-6Al-4V vehicle lower arm preform

Cited by 8 publications

References 30 publications

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

A Modified Arrhenius‐Type Constitutive Model and its Implementation by Means of the Safe Version of Newton–Raphson Method

The Comparation of Arrhenius-Type and Modified Johnson–Cook Constitutive Models at Elevated Temperature for Annealed TA31 Titanium Alloy

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