A Study of Friction Model Performance in a Skew Rolling Process Numerical Simulation

Murillo-Marrodán, Alberto; García, Eduardo; Cortés, Fernando

doi:10.2507/ijsimm17(4)441

Cited by 27 publications

(23 citation statements)

References 24 publications

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“…where τ is the shear stress on contact surface, m is the friction factor (set equal to m = 0.8 for the rolls [27] and m = 0.2 for other tools), k is the shear yield stress ( = √3) ⁄ . The model of the material used in the numerical analysis was the 42CrMo4 grade of steel (obtained from the material library database of the program), expressed by the following equation:…”

Section: Materials 2020 13 × For Peer Review 3 Of 21mentioning

confidence: 99%

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A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

Pater

2020

Materials

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The paper presents a comparative analysis of skew rolling in 3- and 4-roll CNC rolling mills. The analysis is performed using the FEM-based commercial simulation software Simufact.Forming. The formation of both solid and hollow railway axles is analyzed. Distributions of effective strain, temperature and damage criterion in rolled axles are determined, and loads and torques acting on the tools during rolling are estimated. An innovative concept of calibrating hollow axles by the rotary compression technique developed at the Lublin University of Technology is presented. Experimental tests of rolling solid axles in a 3-roll rolling mill (in a scale of 1:5) are performed, and basic force parameters of the rolling process are measured. Numerical and experimental loads and torques show a high agreement in terms of both quality and quantity.

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Section: Materials 2020 13 × For Peer Review 3 Of 21mentioning

confidence: 99%

“…where τ is the shear stress on contact surface, m is the friction factor (set equal to m = 0.8 for the rolls [27] and m = 0.2 for other tools), k is the shear yield stress (k = σ F / √ 3). Thermal effects occurring during forming were considered in the analysis.…”

Section: Materials 2020 13 × For Peer Review 3 Of 21mentioning

confidence: 99%

A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

Pater

2020

Materials

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“…Friction was modelled using the Tresca model, assuming that the friction factor at the material/tool interface was 0.8 [18]. In addition, it was assumed that during the compression the tools had a constant temperature of 50°C and the coefficient of heat transfer between the specimen and tools was 10,000 W/m 2 K.…”

Section: Fem Analysis Of Rotational Compression Between Channel-diesmentioning

confidence: 99%

Determination of the critical value of damage in a channel-die rotational compression test

et al. 2019

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This article describes the problems involved in modelling material cracking in skew rolling processes. The use of the popular damage criteria is impossible because of the lack of a calibration test that would make it possible to determine the critical value of material damage under conditions similar to those found in skew rolling. To fill this gap, a test called channel-die rotational compression was proposed. It consisted of rolling a disk-shaped specimen in a cavity created by two channels of cooperating tools (flat dies), which had heights smaller than the diameter of the specimen. When the rolling path was sufficiently long, a crack formed in the axial zone of the specimen. In this test, modelling using the finite element method made it possible to determine the critical values of material damage. As an illustration, the test was used to determine the critical damage value when conducting a rotational compression process on 50HS steel (1.5026) specimens formed in the temperature range of 950-1200°C. The analysis was conducted using the Cockcroft-Latham damage criterion.

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“…More recent studies are focussed on increasing model accuracy by reducing assumptions on boundary conditions or by reproducing the different phenomena occurring in the RTP process. Murillo-Marrodán et al [14] showed the importance of the correct selection of boundary conditions for the reliability of model results and conclusions. Another aspect that enhances the model accuracy is the correlation of strain.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Wall Thickness Eccentricity in the Rotary Tube Piercing Process Using a Strain Correlated FE Model

Murillo-Marrodán

García

Barco³

et al. 2020

Metals

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The wall thickness eccentricity is one of the most important weaknesses that appears in seamless tubes production, since this imperfection is subsequently transferred downstream through the manufacturing stages until the final product. For this reason, in this article a finite element model of the rotary tube piercing (RTP) process is developed aimed at analysing the wall thickness eccentricity imperfection. Experimental data extracted from the industrial process is used for the validation of the model, including operational process variables like power consumption and process velocity, and deformation variables as elongation and longitudinal torsion, originated by axial and shear strain respectively. The cause of longitudinal torsion is also analysed. The two most important conclusions derived from this study are: (I) the longitudinal torsion of the tube is a crucial parameter for the correct model validation, and (II) the combined effect between the uneven temperature distribution of the billet and the plug bending deformation is identified as the major cause of the wall thickness eccentricity flaw.

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A Study of Friction Model Performance in a Skew Rolling Process Numerical Simulation

Cited by 27 publications

References 24 publications

A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

Determination of the critical value of damage in a channel-die rotational compression test

Analysis of Wall Thickness Eccentricity in the Rotary Tube Piercing Process Using a Strain Correlated FE Model

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