Influence of tool parameters on internal voids in cross wedge rolling of aluminum alloy parts

Jia, Zhi; Zhou, Jie; Ji, Jin-jin; Yu, Yingyan; Xiao, Chuan

doi:10.1016/s1003-6326(12)61678-1

Cited by 20 publications

(6 citation statements)

References 15 publications

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“…The slip on the tool-billet interface, contact stress, wear coefficient and hardness of tool contribute to tool wear behaviors (Meyer et al , 2015). However, due to higher contact temperature, heat is considered as one of the most important factors in CWR process (Jia et al , 2012; Ying and Pan, 2007a, 2007b). As shown in Figure 1, the wear coefficient, Young’s modulus and hardness are all greatly influenced by local contact temperature of tool.…”

Section: Resultsmentioning

confidence: 99%

“…Due to its numerous advantages and great potential, a lot of studies on CWR have been carried out focusing on the analysis of billet stress, strain, temperature and metal flow (Pater, 1998; Ying and Pan, 2007a, 2007b; Pater, 2006), rolling machine selection (Yan et al , 2010), the defect analysis and prevention (Li and Lovell, 2008; Jia et al , 2012; Li and Lovell, 2004). New areas of application for extending CWR application were also explored for the production of special shape billets such as toothed shafts (Neugebauer et al , 2007; Ying, 2007), hollow shafts (Neugebauer et al , 2002a; Neugebauer et al , 2002b), workblank of crankshafts (Meyer et al , 2015), eccentric shaft (Ji et al , 2014; Pater, 2011; Zheng et al , 2010) as well as ball pin (Pater, 2013; Pater et al , 2005).…”

Section: Introductionmentioning

confidence: 99%

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Wear resistance behavior of striated tool for cross wedge rolling

Huang

Liu

Fan

et al. 2018

ILT

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Purpose The purpose of this paper is to investigate the wear resistance behavior of the striated tool for cross wedge rolling (CWR). Design/methodology/approach A mechanical-thermal coupled, temperature-dependent FE wear model was developed to explore the wear behaviors for striated CWR tools. To verify the proposed FE model, a newly developed measuring device was also developed to measure wear on the tool ridge. To find the impact order of the parameters of striate unit, orthogonal experiment was carried out. Findings The experimental and numerical results both indicate that the wear resistance of striated tool is better than that of smooth tool. Minimum tool ridge wear can be achieved by choosing proper tool contact temperature with striated units on crossed ridge. The order of the striation geometrical factors’ impact on ridge wear is striation width > striation interval > striation length. Research limitations/implications Because of the specified tool, the research results may lack generalizability. Therefore, researchers are encouraged to test the proposed propositions further. Originality/value It is shown that the wear resistance of striated CWR tool is better than that of smooth tool. The information may help CWR manufactures to design and produce tools with less wear.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Wear resistance behavior of striated tool for cross wedge rolling

Huang

Liu

Fan

et al. 2018

ILT

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“…Pater et al [ 92 ] studied the CWR process for producing toothed and screw shafts made of 2816 alloy. Jia et al [ 93 ] investigated the effect of CWR parameters on the internal crack formation in parts made of 7075 alloy. Wang et al [ 94 , 95 ] investigated the effect of billet temperature in the cross-wedge rolling of 6082 alloy shafts.…”

Section: Cwr Formation Of Parts Made Of Non-ferrous Materialsmentioning

confidence: 99%

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Pater

2023

Materials

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The aim of this article is to review the application of the finite element method (FEM) to cross-wedge rolling (CWR) modeling. CWR is a manufacturing process which is used to produce stepped axles and shafts as well as forged parts for further processing on forging presses. Although the concept of CWR was developed 140 years ago, it was not used in industry until after World War 2. This was due to the limitations connected with wedge tool design and the high costs of their construction. As a result, until the end of the twentieth century, CWR tools were constructed by rolling mill manufacturers as they employed engineers with the most considerable experience in CWR process design. The situation has only changed recently when FEM became widely used in CWR analysis. A vast number of theoretical studies have been carried out in recent years, and their findings are described in this overview article. This paper describes nine research areas in which FEM is effectively applied, namely: the states of stress and strain; force parameters; failure modes in CWR; material fracture; microstructure modeling; the formation of concavities on the workpiece ends; CWR formation of hollow parts; CWR formation of parts made of non-ferrous materials; and new CWR methods. Finally, to show the potential of FEM on CWR modeling, a CWR process for manufacturing a stepped shaft used in car gearboxes is simulated numerically. This numerical simulation example shows that FEM can be used to model very complex cases of CWR, which should lead to a growing interest in this advanced manufacturing technique in the future.

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“…Using the same program and ductile fracture criterion, Silva et al [11] modelled material fracture by the killing element technique, under which the elements are deleted when the critical damage is reached (its value being determined by standard tensile testing). In 2012, Jia et al [12] used Deform-3D and a porous material model to determine the effect of basic parameters of the CWR process on the initiation of fracture in 7075 aluminium alloy specimens. Cakircali et al [13] investigated the fracture of Ti6Al4V alloy using the Johnson and Cook criterion and LS-DYNA program.…”

Section: Introductionmentioning

confidence: 99%

Determination of the Critical Value of Material Damage in a Cross Wedge Rolling Test

et al. 2021

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This study investigates the problem of material fracture in cross wedge rolling (CWR). It was found that this problem could be analysed by means of well-known phenomenological criteria of fracture that are implemented in commercial FEM (Finite Element Method) simulation programs for forming processes. The accuracy of predicting material fracture depends on the critical damage value that is determined by calibration tests in which the modelled and real stresses must be in good agreement. To improve this accuracy, a new calibration test is proposed. The test is based on the CWR process. Owing to the shape of the tools and test piece used in CWR, the forming conditions in this process deteriorate with the distance from the centre of the test piece, which at a certain moment leads to fracture initiation. Knowing the location of axial crack initiation in the specimen, it is possible to determine the critical value of material damage via numerical simulation. The new calibration test is used to determine the critical damage of 42CrMo4 steel subjected to forming in the temperature range of 900–1100 °C. In addition, 12 criteria of ductile fracture are employed in the study. The results show that the critical damage significantly increases with the temperature.

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Influence of tool parameters on internal voids in cross wedge rolling of aluminum alloy parts

Cited by 20 publications

References 15 publications

Wear resistance behavior of striated tool for cross wedge rolling

Wear resistance behavior of striated tool for cross wedge rolling

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Determination of the Critical Value of Material Damage in a Cross Wedge Rolling Test

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