Numerical Analysis and Parameter Optimization of Wear Characteristics of Titanium Alloy Cross Wedge Rolling Die

Peng, Zhanshuo; Ji, Hongchao; Huang, Xiaomin; Wang, Baoyu; Xiao, Wenchao; Wang, Shufu

doi:10.3390/met11121998

Cited by 6 publications

(3 citation statements)

References 41 publications

(54 reference statements)

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“…Finally, the study is focused on a specific application and material, so the findings may not be directly applicable to other materials or applications. [35] The paper uses a combination of finite element analysis (FEA) and multi-body dynamics (MBD) to simulate the contact and wear behavior of the cervical total disc arthroplasty and applies the Archard wear model to predict the wear volume and wear rate of the ultrahigh-molecular-weight polyethylene insert.…”

Section: Archard Wearmentioning

confidence: 99%

Wear Analysis of NiTi Sand Screens Using Altair Discrete Element Method

Amadi,

Mohyaldinn,

Abduljabbar

et al. 2024

Materials

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This research explores discrete element method analysis to investigate the wear of NiTi Sand Screens in comparison to traditional materials. The study utilized Altair EDEM v2022.2 software and employed Oka and Archard models to simulate the wear behavior of Nitinol, a well-established Shape Memory Alloy (SMA). The mechanical properties considered include Poisson’s ratio, solid density, shear modulus, and Young modulus. Results indicate significantly higher wear values and deformations with the Oka model compared to negligible wear with the Archard model. The Oka model’s emphasis on impact as the primary wear mechanism, supported by high normal cumulative energy, better represents sand screen wear phenomena. Additionally, this study indicates that factors such as particle size distribution and normal and tangential cumulative contact energy hold potential as predictors of wear response and characteristics. The Oka model demonstrated that NiTi exhibited reduced wear losses compared to SUS630 and Cr–Mn white cast iron, both of which are recognized for their high toughness when subjected to an impact load. Experimental analysis validated the simulation findings with morphological and graphical erosion plots. The limitation of observing the shape memory effect through DEM (discrete element method) simulation was acknowledged. Recommendations include characterizing post-wear microstructural changes, exploring the influence of temperature on wear behavior, and further research to refine wear models and understand SMA sand screen responses.

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Section: Archard Wearmentioning

confidence: 99%

Wear Analysis of NiTi Sand Screens Using Altair Discrete Element Method

Amadi,

Mohyaldinn,

Abduljabbar

et al. 2024

Materials

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“…Ji et al [ 86 ] modeled the CWR of a blade preform. Peng et al [ 87 ] analyzed 46 cases of CWR to determine wear characteristics of the wedge tools. Li et al [ 88 , 89 ] investigated the CWR of a vehicle arm preform to determine the optimum temperature of the billet.…”

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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“…In the research of plastic forming, the wear problem is mainly reflected in extrusion [3,4], stamping [5,6], rolling [7][8][9], and so on. Tonn [10] first proposed the formula for calculating abrasive wear in 1937.…”

Section: Introductionmentioning

confidence: 99%

Prediction and Optimization of Wear Depth on Rectangular Tube Surface in Roll Forming

Xing

Liu

Wang

et al. 2022

Metals

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The outer surface of the tube is worn under the interaction between the velocity difference and rolling pressure, in the process of rolling the circular tube into a rectangular tube. In order to predict the wear depth, according to the characteristics of roll forming, the causes of wear in the forming process are analyzed. The finite element model of rolling forming was established based on Archard theory, and the 40 mm × 27.5 mm × 3 mm SUS304 stainless steel rectangular tube was simulated. The simulated results were compared with a test rolling of the steel tubes of the same size material, and the wear areas were found to be highly consistent, which verified the accuracy of the finite element model. The effects of the friction coefficient and the flat roller angular velocity on the simulation results which wear depth were analyzed, and the regression model of wear depth was established by response surface method. The results showed that the flat roller angular velocity had the greatest effect on wear depth; moreover, the flat roller friction coefficient was the second, and the vertical roller friction coefficient was the lowest. The minimum value of the regression model was optimized, the simulation value of the optimization scheme was compared with the optimized value, and the error of the two values was less than 5%, which verified the correctness of the regression model. The wear depth of the rectangular tube after optimization was reduced by 64.69% compared with that before optimization, which verified the effectiveness of the optimization results.

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Numerical Analysis and Parameter Optimization of Wear Characteristics of Titanium Alloy Cross Wedge Rolling Die

Cited by 6 publications

References 41 publications

Wear Analysis of NiTi Sand Screens Using Altair Discrete Element Method

Wear Analysis of NiTi Sand Screens Using Altair Discrete Element Method

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

Prediction and Optimization of Wear Depth on Rectangular Tube Surface in Roll Forming

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