The safety of basic parts of the rolling equipment is most at risk due to the complex geometrical shape and significant levels of nominal stresses. With a significant mass of such parts and a long production time, the replacement process is accompanied by the need to dismantle the old mill and install a new one. Currently, there are no specialized methods for assessing the risks of failures in relation to the rolling equipment, therefore, it is required to develop new methodological provisions and adapt the existing general methods of risk assessment to real production conditions. Based on the fundamentals of the regulatory document, a methodology for assessing the risks of failures in relation to the rolling equipment has been developed. The roughing stand of the “2000” hot rolling mill for titanium alloy sheet production was chosen as a practical object for assessing the risks of failure. The preliminary analysis of the dangers and their consequences had shown that for most of the elements of the working stand, which perceive the rolling force, as well as for the units and parts of the main drive loaded with the rolling torque, there are dangers that can lead to disruption of the deadlines for fulfilling orders for rolled products. For a numerical assessment of these risks, special calculations were performed.
Deformation of shafts and seamless tubes are carried out by a radial forging machine in order to achieve the required dimensions and improve the mechanical parameters of the material. Hence, the study of improving the performance of the radial machine leads to an increase in the quality of the forged tube, while the machine equipment in the process of radial forging will have the least erosion. In this process, the workpiece is surrounded by four tools and during the repeated blows of the die, the desired dimensions of the workpiece are obtained. with regards to the contact surface of the die with the workpiece, the most common tool that faces the highest erosion is the die. Therefore, the improvement of die geometry in order to minimize wear has been investigated in this article. Also, the distribution of die temperature and analysis of die stress during the process has been implemented. Accordingly, three types of die geometries: Flat, Concave and Convex are considered to measure the depth of wear and determine the maximum erosion through 3D finite element simulation and experimental estimates. Therefore, according to the comparison between numerical and analytical results in the case of wear analysis with experimental results, the validation of simulation was confirmed.
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