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

Pater, Z.

doi:10.1051/matecconf/20168013001

Cited by 7 publications

(3 citation statements)

References 29 publications

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“…This software was used by the Authors many times for the analysis of skew and cross rolling processes [11][12][13][14][15][16][17] and calculations results were in good conformity with experimental research results, verifying these calculations.…”

Section: Numerical Model Of Skew Rolling Process Of a Rail -Coach Axlementioning

confidence: 55%

Numerical Analysis of the Skew Rolling Process for Rail Axles

Pater¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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The paper describes a new method for producing stepped rail axles. The method is based on the skew rolling process. With this method, the product is formed by three tapered rolls located every 120• on the perimeter of the billet. Positioned askew to the centerline of the billet, the rolls rotate in the same direction and with the same velocity. At the same time, they get closer together or go apart depending on the desired cross sectional reduction of an axle step. In addition, the workpiece is shifted lengthwise relative to the rolls by the translational motion of the workpiece-holding chuck. In order to verify the designed method for producing rail axles, a series of numerical simulations were performed using the Simufact.Forming v.12 simulation software. The numerical modeling enabled the determination of maps of the effective strain and temperature in the finished product as well as variations in the loads and torques during rolling. The numerical results unambiguously confirm that the skew rolling method can be applied to form parts of considerable dimensions (the modeled axles had a length of 2146 mm and their maximum diameter was 202 mm).Keywords: Skew rolling, rail axle, FEM W artykule opisano metodę wytwarzania stopniowanej osi wagonowej bazującą na procesie walcowania skośnego. W metodzie tej wyrób kształtowany jest za pomocą trzech rolek stożkowych, rozmieszczonych na obwodzie wsadu co 120• . Rolki te ustawione są skośnie względem osi wsadu, a w trakcie kształtowania obracają się z jednakową prędkością w tę sa-mą stronę oraz jednocześnie zsuwają lub rozsuwają się -w zależności od redukcji przekroju poprzecznego kształtowanego stopnia osi. Dodatkowo, wyrób kształtowany przesuwany jest wzdłużnie względem rolek, w wyniku ruchu postępowego uchwytu utwierdzającego jeden z jego końców. Sprawdzenia poprawności założonej koncepcji kształtowania osi wagonowej dokonano w drodze symulacji numerycznej wykonanej w programie Simufact.Forming v.12. W efekcie wykonanych obliczeń uzyskano mapy intensywności odkształcenia i temperatury w ukształtowanym wyrobie oraz wyznaczono przebiegi sił i momentów w trakcie walcowania. Jednoznacznie potwierdzono możliwość kształtowania wyrobów o dużych gabarytach (długość osi wynosi 2146 mm, a jej średnica maksymalna 202 mm) metodą walcowania skośnego.

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Section: Numerical Model Of Skew Rolling Process Of a Rail -Coach Axlementioning

confidence: 55%

Numerical Analysis of the Skew Rolling Process for Rail Axles

Pater¹,

Tomczak²,

Bulzak³

2015

Archives of Metallurgy and Materials

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“…Rolls used in helical-wedge rolling (top) and 33 mm diameter balls formed by these tools (down) [68] The satisfactory results of the helical wedge rolling technique for producing balls led a team of researchers from Lublin University of Technology to investigate if this new manufacturing technique could be used for manufacturing some other parts. The results of the FEM numerical analyses described in detail in [64,65,93] demonstrate that the helical rolling method can be used to produce fixings, stepped shafts and bodies of rotary cutters (Fig. 20).…”

Section: Helical Rollingmentioning

confidence: 97%

Overview of the Research on Roll Forging Processes

Tofil¹,

Pater²

2017

Adv. Sci. Technol. Res. J.

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The paper overviews the research on roll forging processes in the last two decades. Given the broad scope of this problem, the overview focuses on processes in forging plants, omitting those performed in metallurgical plants. Three rolling processes are discussed in detail: longitudinal rolling, cross rolling and helical rolling. Each of the three techniques is discussed in terms of the main research problems and potential directions of future development.

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“…The increase of balls manufacturing efficiency is sought in the application of cross-wedge rolling methods during their production, which allow for forming of a few balls simultaneously at relatively small waste [2][3][4]. Better results can be obtained using continuous forming method, which is, by no means, developed by the Author helical-wedge rolling (HWR) [5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Helical Rolling Process of Balls Formed From a Head of a Scrapped Rail

Pater¹

2016

Adv. Sci. Technol. Res. J.

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This paper presents an innovative helical rolling process of balls destined for mills manufactured from a scrapped rail head. In this process, helical rolls are applied, whose construction allows obtaining a cylindrical bar, and later balls are formed from this bar in the further stage of the process. It is advised to precede the rolling process by side pressing leading to increase of billet material shape compactness. Verification of the assumed solution correctness was made using numerical simulation, with the application of Simufact.Forming software.

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

Cited by 7 publications

References 29 publications

Numerical Analysis of the Skew Rolling Process for Rail Axles

Numerical Analysis of the Skew Rolling Process for Rail Axles

Overview of the Research on Roll Forging Processes

Analysis of Helical Rolling Process of Balls Formed From a Head of a Scrapped Rail

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