Numerical and Experimental Study on the Thermodynamic Coupling of Ti-6Al-4V Blade Preforms by Cross Wedge Rolling

Ji, Hongchao; Dong, Jianwei; Xin, Long; Huang, Xiaomin; Liu, Jinping

doi:10.3390/met8121054

Cited by 6 publications

(4 citation statements)

References 37 publications

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“…Li et al [ 85 ] examined the effect of the CWR parameters ( α , β , T , and Δ A ) on the shape and dimensions of a rolled part. Ji et al [ 86 ] modeled the CWR of a blade preform. Peng et al [ 87 ] analyzed 46 cases of CWR to determine wear characteristics of the wedge tools.…”

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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“…The Arrhenius equation can accurately describe the constitutive equation of TC4 alloy at high temperatures [22,23]. The material constants can be determined separately according to the isothermal compression test data at different strain rates and temperatures.…”

Section: Determination Of Materials Constantsmentioning

confidence: 99%

“…He pointed out that this was caused by the elliptical deformation of the rolled workpiece in the rolling process. Ji et al [22] studied the temperature distribution, force energy parameters and forming accuracy of the TC4 alloy blade preforms during the rolling process by CWR. Li et al [23] studied the effects of die parameters and initial rolling temperature on the surface quality of TC4 alloy during CWR process.…”

Section: Introductionmentioning

confidence: 99%

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

Wang

Feng

et al. 2021

Int J Adv Manuf Technol

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Cross wedge rolling (CWR) has unique advantages in the production of shaft preforms with refined grains and improved mechanical properties. Considering the sensitivity of Ti-6Al-4V (TC4) alloy to heat treatment temperature, the effect of different initial deformation temperatures (IDTs) on the forming quality, mechanical properties and microstructure evolution of the TC4 alloy lower arm preforms in CWR forming were studied in this work. The flow stress curves of TC4 alloy in the two-phase region were obtained by isothermal compression experiments. The Arrhenius constitutive model was established and applied to DEFORM-3D finite element (FE) software to simulate the CWR forming process of TC4 alloy lower arm preforms. The forming quality of TC4 alloy parts was compared and analyzed by 3D FE simulation and experiment. And their mechanical properties at room temperature were tested by tensile test. The results showed that the rolled part has well forming quality (no steps and necking defects) and higher geometric dimension accuracy at the IDT 850°C. Moreover, with the increase of IDT, the radial force and torque in the rolling process decrease. In addition, there were no internal defects in the parts rolled by different IDTs, because the die gap reduces the number of alternating cycles of tensile-compressive stress in the rolled workpieces.Compared with the initial state, the microstructure was refined. When the IDT is 885 °C, the ultimate tensile strength (UTS), yield strength (YS) and elongation (EI) of the parts were 987 MPa, 924 MPa and 16.8 % respectively, which was able to ensure the mechanical performance requirements of the lower arm preform. The results provide theoretical guidance for the actual production of lower arm preform by CWR.

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“…Titanium alloys are widely used in the aerospace industry to make important parts such as the turbine blades and discs in jet engines. This is due to their superior properties including their high strength at high temperatures, resistance to corrosion and high strength-to-weight ratio [1]. The superior properties of these alloys, however, also make them very difficult to machine [2].…”

Section: Introductionmentioning

confidence: 99%

Experimental Study and Numerical Simulation of the Intermittent Feed High-Speed Grinding of TC4 Titanium Alloy

Jiao

Zhou

Deng

2019

Metals

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This paper proposes intermittent feed high-speed grinding, which shows considerable advantages in terms of reducing grinding temperature, relieving grinding wheel blockage and improving workpiece surface integrity. In this grinding, the continuous feed mode of the workpiece is changed into the normal feed + fast retreat reciprocating feed mode by a fast linear feed worktable. By reasonably setting the normal feed distance of single grinding, the action time of the grinding wheel and workpiece is reduced, so that the grinding heat transfer process does not reach a stable state, reducing the grinding temperature during single grinding. Besides this, the surface temperature is cooled to nearly room temperature and the grinding wheel is flushed by the timely retreating of the grinding wheel to allow the grinding fluid to enter the grinding zone fully, which greatly reduces the phenomenon of heat accumulation and grinding wheel loading. An intermittent feed high-speed grinding experiment on Ti-6Al-4V (TC4) titanium alloy was systematically carried out, and the influence of the grinding parameters on grinding force and grinding temperature was deeply analyzed. The instantaneous grinding temperature field and thermal stress field of TC4 titanium alloy in intermittent feed high-speed grinding were constructed with the finite element method. The surface morphology of the grinding wheel and TC4 titanium alloy specimens after intermittent feed grinding were analyzed and were compared with those after traditional continuous grinding. It was found that the curves of the grinding force and temperature varied with time in the process of machining, consisting of many “pulse” peaks. Under the same grinding parameters, the magnitude of the grinding force is the same as that of continuous grinding. In a certain range, the grinding temperature is greatly affected by the single feed distance and the interval time. The numerical simulation results are in good agreement with the experimental results, and the error is controlled within 12%. Compared with traditional high-speed grinding, under the same process parameters, the grinding temperature is greatly reduced, the surface integrity of the workpiece is better, and the clogging of the grinding wheel is greatly reduced.

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Numerical and Experimental Study on the Thermodynamic Coupling of Ti-6Al-4V Blade Preforms by Cross Wedge Rolling

Cited by 6 publications

References 37 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

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

Experimental Study and Numerical Simulation of the Intermittent Feed High-Speed Grinding of TC4 Titanium Alloy

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