Numerical investigation of the radial cold rolling process of the grooves

Abstract

The radial cold rolling process is widely used in industry due to the advantages of chip removing processing. In this study, circular complex profiles were formed by cold-rolling with radial feed, using a patented device with two roller-tools. By achieving several numerical simulations of the radial rolling process, the study aimed to establish the influence that the maximum set force and the diameter of the workpiece have on the productivity of the process and the quality of the formed trapezoidal and metric grooves. The numerical simulations were performed with ABAQUS/Explicit software and by using a previously validated finite element model. The penetration curve of the roller-tools in the material was introduced in the simulation as an analytical function and was determined based on experimental researches. To express the dependency of the penetration curve coefficients on other rolling conditions, a multivariable analysis using a design of experiments technique was performed. The parameters that result from numerical simulations and were analyzed in this study are the profile forming time, the maximum radial force, the distribution of the equivalent strains in the axial section of the profiles, and the profile dimensions. The conclusions that were drawn from the analysis of the results regarding the influence of the set maximum force and the workpiece diameter on the analyzed parameters of the numerical simulations, together with the definition of efficient process criteria, allowed also the identification of the optimal conditions of the rolling process.

Effect of process parameters on porosity defects in Al-Si alloy hot rolling

“…During production and processing, the impact of void defects inside a material is ignored in most cases, which often lead to a gap between the mechanical properties of the finished product and theoretical data. 17–20 The damage inside a material was considered in GTN meso-damage model. Every parameter of the model has physical significance, which genuinely reflects the damage mechanism of the material.…”

“…The primary focus of research was to simulate rolling processes with different finite element softwares, then to analyze the influence of various process parameters on the stress–strain relationship and materials’ changes about internal structure and organizational performance during rolling. 14–16 However, researches on the porosity defects of Al-Si alloys have been relatively scarce.…”

Orthogonal Simulation Optimization of GH4169 Bolt Thread Rolling Process Parameters

“…Shuowen Zhang, Shuqin Fan [12] described the principle of the axial self-feed rolling process and determined the prerolling angle that minimizes tooth protrusion through finite element analysis. Eduard Laurentiu Nitu [13] studied the radial feed cold roll forming of round complex profiles. They conducted multivariate analysis using the design of experiments technique and derived mechanical and geometric parameters, such as maximum radial force, through finite element simulation to determine optimal conditions for the rolling process.…”