A numerical model, developed for LS-Dyna solver, aimed to study the wedge rolling process is presented in this article. In addition, a comparison is made between the experimental and simulated results in order to set up the numerical model’s definition and simulation parameters. The computational performances are evaluated throughout this article to identify the best practice parameters for cold rolling numerical analysis using wedge tools. For an evaluation of the performances of the numerical model, an experimental system was developed to analyse the process parameters of the complex profiles with grooves formed by wedge tools. The methodologies used to record and evaluate the experimental results and the capabilities of the technique are discussed. For a complete analysis, the material behaviour is described by using a five-parameter strain-hardening law. Both the radial force (process force) and the micro-hardness were measured using the Vickers method on a radial section of the rolled piece. The issues addressing the numerical simulation can be extrapolated to other processes (e.g. riveting, flow forming) as this article provides the required information for the development of reliable numerical models.
. Simulation of the FSW process is a complex issue, as it implies interactions between thermal and mechanical phenomena and the quality of the welding depends on many factors. In order to reduce the time of the experimental tests, which can be long and expensive, numerical simulation of the FSW process has been tried during the last ten years. However, there still remain aspects that cannot be completely simulated.
In this paper the authors present the steps of the numerical simulation using the finite elements method, in order to evaluate the boundary conditions of the model and the geometry of the tools by using the Arbitrary Lagrangian Eulerian (ALE) adaptive mesh controls.
Welding dissimilar materials aluminum and copper by FSW are of great interest because Al and Cu are two most common engineering materials widely used in many industries. The paper analyzes the microstructure and mechanical properties obtained by butt of dissimilar material Cu - Al alloys (EN-AW-5754) by FSW. The joining by FSW process of the two samples (5 mm thickness) was performed with the pin of the tool tangential to copper plate. The values of the process parameters were the same in both cases: the rotation speed of the pin 1200 [rpm] and feed rate 60 [mm / min]. The microstructure was examined in 6 zones covering the whole thickness of the plates, Vickers microhardness was measured along a perpendicular line to the nugget and residual stresses.
This study is part of the concerns that the authors have had in recent years, representing an extension of a research project funded consisting in modelling representative cold rolling processes of profiles. This paper presents a comparative analysis of quality of the superficial layer of a circular profile (grooves) obtained by two different processes: radial rolling with two roller tools and turning with radial feed. Also, the two processes are compared from the viewpoint of economic efficiency. The materials used for the experiments are frequently used to obtain pieces with circular grooves: two types of cementation steel and two types of heat treatable steel. The characteristics of the superficial layer which describe its quality and which are comparatively analyzed in connection to the two processes are: roughness, microstructure and micro-hardness. The economic efficiency of the two processes was assessed by means of the costs implied and the productivity of processing. The interpretation of the results obtained enabled stressing the advantages to generate circular grooves by cold radial rolling from the point of view of the quality of the superficial layer of pieces, as well as the limits of the use of this process from the viewpoint of economic efficiency.
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