Numerical analysis of a skew rolling process for
producing a crankshaft preform

Lis, Konrad; Wójcik, Łukasz; Pater, Z.

doi:10.1515/eng-2016-0087

Cited by 21 publications

(18 citation statements)

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“…To determine the critical damage value with the proposed rotary compression in cavity test, this process must be numerically modelled by the finite element method. The present analysis is performed with the use of the Simufact.Forming simulation software which was effectively used in previous studies into processes such as cross wedge rolling [43][44][45], Mannesmann piercing [30,46,47], helical rolling of balls [48][49][50], three-roll skew rolling [35,51,52] and other rolling processes [53][54][55][56][57]. performed under laboratory conditions.…”

Section: Fem Analysismentioning

confidence: 99%

“…The results demonstrated that the highest damage value occurs in the loci where the balls get separated. The NCL criterion of ductile fracture was also investigated with respect to skew rolling performed in a numerically controlled three-roll mill [35]. Using Simufact.Forming, the authors analysed the rolling process for producing a crankshaft preform.…”

Section: Introductionmentioning

confidence: 99%

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Rotary compression in tool cavity—a new ductile fracture calibration test

Pater

Tomczak

Bulzak

et al. 2020

Int J Adv Manuf Technol

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Ductile fracture is one of the most common failure modes in hot metal forming. It can be predicted by means of so-called damage functions that describe the relation between stress, deformation and fracture initiation. A practical use of these functions requires the knowledge of the critical damage value of the material that is determined by calibration tests based on compression, tension and torsion. For the prediction to be correct, one must ensure that the modelled and real stresses are in agreement. Previous studies did not offer any effective test for determining critical values of damage under changing load conditions that occur in cross and skew rolling processes, among others. To compensate for this knowledge gap, researchers at the Lublin University of Technology have developed a new test consisting in rotary compression of a test-piece in a cavity between the tools, which is described in this paper. In the proposed test, a cylindrical test-piece is rolled over a cavity (impression) created by grooves on two mating tools. The cavity height is smaller than the test-piece diameter. At the critical value of the forming length, the state of stress induced thereby in the test-piece axis causes fracture. Knowing the critical forming length, it is possible to determine the critical value of damage by numerical modelling. The practical application of the proposed test is illustrated through the case of C45 grade steel subjected to forming in the temperature range 950-1150°C. The analysis makes use of the normalized Cockcroft-Latham (NCL) criterion of ductile fracture.

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Section: Fem Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Rotary compression in tool cavity—a new ductile fracture calibration test

Pater

Tomczak

Bulzak

et al. 2020

Int J Adv Manuf Technol

Self Cite

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“…Numerical simulations of the CWR test were performed in Simufact.Forming (v.15, MSC Software Company, Hamburg, Germany). This program was previously used to analyse numerous processes, such as the cross wedge rolling of shafts and axles [ 35 , 36 , 37 ], tube rolling [ 38 , 39 , 40 ], the helical rolling of balls [ 41 , 42 , 43 ], three-roll skew rolling [ 44 , 45 , 46 ] and cross rolling [ 47 , 48 , 49 , 50 , 51 ]. The numerical results of these studies showed high agreement with validating experimental data.…”

Section: Numerical Analysis and Validation Of The Numerical Modelmentioning

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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“…Forming v.15 software, based on FEM. This software was used for analyses of cross-and skew-rolling processes multiple times [41,42,[45][46][47][48][49], and the results of calculations remained compliant with the results of experimental testing.…”

Section: Numerical Analysismentioning

confidence: 99%

Rotational Compression of Cylindrical Specimen As a New Calibrating Test for Damage Criteria

et al. 2020

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The subject-matter of the article is the ductile fracture of materials—A phenomenon occurring in numerous metal forming processes. In order to prognosticate the possibility of a fracture, damage criteria are employed. Their effectiveness, however, depends on the accurate determination of the critical values of damage. These values are obtained through calibrating tests, where the stress state has to be as similar to the actual process as possible. The currently employed calibrating tests do not enable one to determine the limit values of the damage function when the Mannesmann effect occurs. Therefore it was not possible to effectively prognosticate the material fracture in the processes of cross- and skew-rolling. A new calibrating test, based on rotational compression of a cylindrical sample, in which the fractures are caused by the Mannesmann effect, was developed at the Lublin University of Technology. This test was discussed in the article, with a particular focus on the stress and strain state in the sample. A practical use of the test was presented on the example of C45 grade steel, formed in the temperature equal 1150 °C. In the research ten material damage criteria were adopted.

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Numerical analysis of a skew rolling process for producing a crankshaft preform

Cited by 21 publications

References 0 publications

Rotary compression in tool cavity—a new ductile fracture calibration test

Rotary compression in tool cavity—a new ductile fracture calibration test

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

Rotational Compression of Cylindrical Specimen As a New Calibrating Test for Damage Criteria

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