Numerical Analysis of the Cross-Wedge Rolling Process by Means of Three Tools of Stepped Shafts From Aluminum Alloy 7075

Bartnicki, J.; Tomczak, J.; Pater, Z.

doi:10.1515/amm-2015-0071

Cited by 9 publications

(4 citation statements)

References 5 publications

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“…Similar limitations apply to the cross-wedge rolling and rolling-extrusion technologies for hollow part forming presented in the earlier works of Lublin University of Technology [17,18]. An important advantage of the new solution is the possibility of forming various shapes of products without changing tools, using only the change of the speed of the movement of the tools in relation to each other.…”

Section: Introductionmentioning

confidence: 76%

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

2021

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The paper presents chosen aspects of the skew rolling process of hollow stepped products with the use of a skew rolling mill designed and manufactured at the Lublin University of Technology. This machine is characterized by the numerical control of spacing between the working rolls and the sequence of the gripper axial movement, which allows for the individual programming of the obtained shapes of parts such as stepped axles and shafts. The length of these zones and the values of possibly realizable cross-section reduction and obtained outlines are the subject of this research paper. The chosen results regarding the influence of the technological parameters used on the course of the process are shown in the present study. Numerical modelling using the finite element method in Simufact Forming, as well as the results of experimental tests performed in a skew rolling mill, were applied in the conducted research. The work takes into account the influence of cross-section reduction of the hollow parts and the feed rate per rotation on the metal flow mechanisms in the skew rolling process. The presented results concern the obtained dimensional deviations and changes in the wall thickness determining the proper choice of technological parameters for hollow parts formed by the skew rolling method. Knowledge about the cause of the occurrence of these limitations is very important for the development of this technology and the choice of the process parameters.

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Section: Introductionmentioning

confidence: 76%

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

2021

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“…The issue of the use of a mandrel in the cross-wedge rolling process has been addressed, among others, by Shen et al [ 15 ]. In the course of conducting research, Bartnicki et al [ 16 ] proved that the best conditions for forming hollow products in the cross-wedge rolling process occur when three rolling tools are used. Based on the assumption that hollow products should be rolled with three rollers, a rotary compression process was developed and analysed by Tomczak et al [ 17 ].…”

Section: Introductionmentioning

confidence: 99%

Assessment of the Susceptibility to Material Fracture in the Cross-Wedge Rolling Process with Concave Tools

Bulzak

2022

Materials

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The internal cracking of forgings during the cross-wedge rolling (CWR) process is a serious limitation that prevents the correct implementation of this process. The phenomenon of material cracking in the CWR process reduces the technological and application possibilities of this highly efficient process, which can produce forgings with high geometric accuracy. This article presents the results of rolling forgings at different temperatures. An analysis of the results showed that the size of the resulting material fracture in the CWR process is related to the size of the ovalisation of the cross-section of the forging formed during rolling. On the basis of the observations made, it was proposed to realise the cross-wedge rolling process with concave tools. The use of tools with a concave geometry is intended to reduce the excessive flow of material in the rolling direction, which restrains the formation of the ovalisation of the cross-section of the forging. Numerical simulations were carried out comparing the rolling with flat tools and concave tools with different radii of the curvature. The results show that the use of concave tools reduces the ovality of the cross-section of the forging during rolling and reduces the value of the normalised Cockcroft–Latham (CL) fracture criterion.

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“…The mill, which uses two sets of tools (an upper and a lower tool set), allows one to roll, in one duty cycle (the advance and return of the hydraulic cylinder), one product in two operations or two products, each requiring one operation [10]. In the literature, one can also find theoretical considerations concerning cross-wedge rolling of hollow products in a three-roll system [11].…”

Section: Introductionmentioning

confidence: 99%

A Comparative Study of Helical and Cross-Wedge Rolling Processes for Producing Ball Studs

et al. 2019

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This paper presents two rolling technologies: cross-wedge rolling (CWR) and helical-wedge rolling (HWR). The two rolling processes were compared using the example of rolling a ball stud forging. The technologies were modeled in the finite element model (FEM) environment. Calculations were performed to obtain distributions of strain and the Cockcroft–Latham damage criterion. The investigated processes were also performed under real-life conditions. The results of the experiments were used to compare the force and energy parameters of the rolling technologies. Tests were also carried out to investigate the microstructure of the studs and a grain size after rolling. The state of the macrostructure, i.e., the grain flow lines, was also compared. The experiments showed that HWR was a more energy-efficient process.

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Numerical Analysis of the Cross-Wedge Rolling Process by Means of Three Tools of Stepped Shafts From Aluminum Alloy 7075

Cited by 9 publications

References 5 publications

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

Assessment of the Susceptibility to Material Fracture in the Cross-Wedge Rolling Process with Concave Tools

A Comparative Study of Helical and Cross-Wedge Rolling Processes for Producing Ball Studs

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