Simulation of tube forming process in mannesmann mill

Lu, Lu; Wang, Zhaoxu; Wang, Fuzhong; Zhu, Guangya; Zhang, Xingxiang

doi:10.1007/s12204-011-1144-1

Cited by 20 publications

(15 citation statements)

References 6 publications

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“…However, the numerical models developed by the mentioned authors were based on significant simplifications -for instance, thermal phenomena occurring in the material were omitted, the calculations were limited only to the initial or steady state of the piercing process, or they assumed that the material being formed is ideally plastic. More developed models of the piercing process which took the thermal phenomena into consideration were presented by Pater et al [6] and Lu et al [7]. The calculation results obtained by means of such models agree with the experimental test results.…”

Section: Introductionsupporting

confidence: 58%

Complex Numerical Analysis of the Tube Forming Process Using Diescher Mill

Pater¹,

Kazanecki²

2013

Archives of Metallurgy and Materials

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This paper presents the results of FEM simulations of the rotary piercing process in which disc guiding devices of the Diescher type are used. During this process the material is formed by means of two skew rolls, two guiding devices, and the piercing plug mounted on the mandrel. The aim of the analysis was to determine the effect of the plug diameter, the plug advance, the feed angle and the diameter reduction on the piercing process. Nine cases of piercing with three different plugs used were analyzed. The effects of the basic process parameters on the tube shell diameter and the tool load were analyzed. The numerical results obtained using Simufact.Forming 10.0 were verified under experimental conditions in which the tube shell made from 100Cr6 bearing steel was pierced. The results of the FEM calculations show agreement with the experimental results.Keywords: tube piercing, Diescher mill, FEM analysis, experiment W artykule zaprezentowano wyniki symulacji numerycznych procesu dziurowania tulei w walcarce skośnej z prowadnicami tarczowymi Dieschera. W procesie tym materiał jest kształtowany w wyniku oddziaływania dwóch ustawionych skośnie walców, dwóch prowadnic oraz główki dziurującej montowanej na trzpieniu. Celem analizy było określenie wpływu średnicy główki, wysunięcia główki, kąta zukosowania walców oraz gniotu na przebieg procesu dziurowania. Przeanalizowano dziewięć przypadków kształtowania, w których wykorzystano trzy rożne główki dziurujące. Określono wpływ podstawowych parametrów procesu na średnicę tulei kształtowanej oraz obciążenie poszczególnych narzędzi. Wyniki symulacji numerycznej otrzymanej w programie Simufact.Forming 10 zweryfikowano w warunkach doświadczalnych, w których dziurowano tuleje ze stali łożyskowej w gatunku 100Cr6. Rezultaty obliczeń MES pozostawały w dobrej zgodności z wynikami uzyskanymi z doświadczeń.

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Section: Introductionsupporting

confidence: 58%

Complex Numerical Analysis of the Tube Forming Process Using Diescher Mill

Pater¹,

Kazanecki²

2013

Archives of Metallurgy and Materials

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“…In accordance with the experimental results presented in [41], the critical NCL damage determined in the tensile test is C = 0.756 ± 0.125 (for C45 steel specimens subjected to tensile testing in the temperature range of 900-1200°C). By applying the critical damage values established in the rotary compression test to predict fracture in the CWR case described in [46], one would ensure agreement between the numerical and experimental results.…”

Section: Resultsmentioning

confidence: 99%

“…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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“…In addition, the computations were limited either to the steady-state stage of the process or to the beginning of the forming process. Complete numerical models of the piercing process for thick-walled tubes taking into consideration thermal phenomena were constructed by several authors only in the last ten years [17][18][19][20][21][22][23][24][25]. The computations were performed with commercial simulation programs such as MSC.…”

Section: Application Of Fem For Analysis Of Helical Rolling Processesmentioning

confidence: 99%

“…The computations were performed with commercial simulation programs such as MSC. SuperForm [15,[21][22][23], Forge [18][19][20], Deform-3D [25]. Other studies were devoted to numerical analysis of elongation processes in helical rolling mills.…”

Section: Application Of Fem For Analysis Of Helical Rolling Processesmentioning

confidence: 99%

FEM Analysis of the Multi-Wedge Helical Rolling Process for a Workholding Bolt

Pater

2016

MATEC Web Conf.

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Abstract. This paper presents the results of a numerical analysis of a helical rolling process for producing a 25 mm diameter workholding bolt using multi-wedge helical tools. The numerical modeling was performed by the finite element method (FEM) using the commercial simulation software Simufact.Forming v. 12. The modeling was performed in a three-dimensional state of strain and included a full thermal analysis. As a result, the changes in workpiece shape as well as the distributions of strains, temperature, damage, loads and torque were determined. The numerical results confirm that workholding bolts can be produced by multi-wedge helical rolling.

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Simulation of tube forming process in mannesmann mill

Cited by 20 publications

References 6 publications

Complex Numerical Analysis of the Tube Forming Process Using Diescher Mill

Complex Numerical Analysis of the Tube Forming Process Using Diescher Mill

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

FEM Analysis of the Multi-Wedge Helical Rolling Process for a Workholding Bolt

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