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

Tofil, Arkadiusz; Tomczak, J.; Bulzak, Tomasz

doi:10.1515/amm-2015-0210

Cited by 22 publications

(11 citation statements)

References 7 publications

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“…The rolling process for the two analysed types of car axles was modelled numerically using Simufact.Forming v.15. This computer simulation software has been successfully used by many researchers to analyse processes such as crosswedge rolling [18][19][20], skew rolling [2,10,[21][22][23][24], and ring rolling [25][26][27], and the numerical results obtained in these studies were in good agreement with the experimental findings.…”

Section: Numerical Model Of the Skew Rolling Process For Rail Car Axlessupporting

confidence: 59%

Forming of rail car axles in a CNC skew rolling mill

Pater

Tomczak

Lis

et al. 2020

Archiv.Civ.Mech.Eng

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This study relates to an innovative method for forming rail car axles by skew rolling in a CNC 3-roll mill. The rolling mill was constructed at the Lublin University of Technology. The use of this machine makes it possible to produce elongated axisymmetric parts that are up to 55 mm in diameter and up to 1000 mm in length. Experimental rolling tests are performed (in 1:5 scale) using this machine. Two types of axles are analysed: one manufactured in accordance with North American standards (AAR Class E) and one manufactured in compliance with European standards (BA302). Diameters of produced axles have a dimensional accuracy of ± 0.4 mm. Produced axles are free from internal cracks, and their surface defects (shallow helical grooves) can easily be removed by machining. The major shortcoming of the proposed method is the presence of chucking allowance. To eliminate this allowance, it is proposed that the forming process should be performed in two operations: rolling extrusion and skew rolling. Results of a numerical analysis were performed using the Simufact.Forming program confirms that rail car axles can be formed by the proposed method.

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Section: Numerical Model Of the Skew Rolling Process For Rail Car Axlessupporting

confidence: 59%

Forming of rail car axles in a CNC skew rolling mill

Pater

Tomczak

Lis

et al. 2020

Archiv.Civ.Mech.Eng

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“…Upon establishing the critical damage values for the nine f i functions the authors conducted the numerical simulation of the CWR process of the harrow tooth preform. The simulation was performer in Simufact.Forming v.15, a software that has been used by the authors to model cross and skew rolling processes [33,34,35,36,37]. The obtained results remained in compliance with the results of the verifying experimental examination.…”

Section: Numerical Modeling Of the Process Of Cross Wedge Rollingsupporting

confidence: 53%

Prediction of Crack Formation for Cross Wedge Rolling of Harrow Tooth Preform

et al. 2019

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The article presents the issue of material fracture during the process of cross-wedge rolling (CWR). The object of the research was the process of forming a harrow tooth preform. In the conducted analysis nine damage criteria were applied. The critical value of damage was determined with a new calibrating test, basing on rotational compression of a sample in a channel. The results of calculations were compared to the results of experimental testing performed in laboratory conditions in Lublin University of Technology. On the basis of the obtained results an assessment of the applied damage criteria and their applicability in the analysis of CWR processes was conducted.

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“…To determine the critical damage value with the proposed rotary compression in cavity test, this process must be numerically modelled by the finite element method. The present analysis is performed with the use of the Simufact.Forming simulation software which was effectively used in previous studies into processes such as cross wedge rolling [43][44][45], Mannesmann piercing [30,46,47], helical rolling of balls [48][49][50], three-roll skew rolling [35,51,52] and other rolling processes [53][54][55][56][57]. performed under laboratory conditions.…”

Section: Fem Analysismentioning

confidence: 99%

Rotary compression in tool cavity—a new ductile fracture calibration test

Pater

Tomczak

Bulzak

et al. 2020

Int J Adv Manuf Technol

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Ductile fracture is one of the most common failure modes in hot metal forming. It can be predicted by means of so-called damage functions that describe the relation between stress, deformation and fracture initiation. A practical use of these functions requires the knowledge of the critical damage value of the material that is determined by calibration tests based on compression, tension and torsion. For the prediction to be correct, one must ensure that the modelled and real stresses are in agreement. Previous studies did not offer any effective test for determining critical values of damage under changing load conditions that occur in cross and skew rolling processes, among others. To compensate for this knowledge gap, researchers at the Lublin University of Technology have developed a new test consisting in rotary compression of a test-piece in a cavity between the tools, which is described in this paper. In the proposed test, a cylindrical test-piece is rolled over a cavity (impression) created by grooves on two mating tools. The cavity height is smaller than the test-piece diameter. At the critical value of the forming length, the state of stress induced thereby in the test-piece axis causes fracture. Knowing the critical forming length, it is possible to determine the critical value of damage by numerical modelling. The practical application of the proposed test is illustrated through the case of C45 grade steel subjected to forming in the temperature range 950-1150°C. The analysis makes use of the normalized Cockcroft-Latham (NCL) criterion of ductile fracture.

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

Cited by 22 publications

References 7 publications

Forming of rail car axles in a CNC skew rolling mill

Forming of rail car axles in a CNC skew rolling mill

Prediction of Crack Formation for Cross Wedge Rolling of Harrow Tooth Preform

Rotary compression in tool cavity—a new ductile fracture calibration test

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