Numerical prediction of ductile damage evolution of 40CrNiMo railway axle steel during hot cross wedge rolling

Jia, Changyuan; Huo, Yuanming; He, Tao; Hosseini, Seyed Reza Elmi; Wu, Wangqing; Huo, Cunlong; Wang, Baoyu

doi:10.1016/j.mtcomm.2022.104942

Cited by 3 publications

(2 citation statements)

References 19 publications

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“…Therefore, the utilization of a ductile fracture criterion to study and predict the cracking behavior of titanium alloys has become a trend. The uncoupled fracture criterion, due to its simplicity and the requirement of fewer calculated parameters, is more favored in industrial applications [13,14].…”

Section: Introductionmentioning

confidence: 99%

Prediction of ductile cracking in the titanium alloy forging process

Fan,

Zhang,

Yuan

2024

Mater. Res. Express

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The control of surface cracking in the forming of titanium alloy forgings is a significant problem in the forging industry. For titanium alloys, the formation of surface cracks is related to temperature, strain rate, and stress state. This study selected the widely used medium to high strength titanium alloy Ti-6Al-4V in the field of forging as the research material, and designed six different shapes of specimens for high-temperature tensile and compression tests. The mechanisms underlying crack formation were analyzed at the microscopic level, and the critical fracture displacement of these tests was extracted. Moreover, their critical fracture strains were obtained through simulations, and a High-temperature damage model was established based on the DF2016 model. The research results showed that cracks through void at grain boundaries propagate and aggregate to form, leading to a fracture mechanism characterized by ductile fracture through micro-pore aggregation. Simulation results demonstrate that the established model accurately predicts the crack of forgings.

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Section: Introductionmentioning

confidence: 99%

Prediction of ductile cracking in the titanium alloy forging process

Fan,

Zhang,

Yuan

2024

Mater. Res. Express

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“…Tomasz et al [9] conducted numerical simulations of railway axles in traditional CWR and MCWR, respectively, and found that the Cockcroft-Latham ductile fracture criterion cannot accurately predict material fracture, while the fracture criterion proposed by Ayada et al can better predict the fracture of railway axles in the process of CWR. Jia et al [10] established the ductile damage model for 40CrNiMo steel and simulated the distribution characteristics of the ductile damage as well as the evolution of the stress state and the Z parameter when 40CrNiMo steel was rolled into the high-speed rail axle at high temperature. It was found that the damage could be decreased by reducing the forming angle, increasing the stretching angle, maintaining the area reduction at 35%, machining the hollow axle, and setting the rolling speed and temperature at 8 r/min and 1273~1323 K. Xu et al [11] used a fast forging machine to forge the square billet into a round shaft billet first, and then rolled the round billet into an axle by CWR.…”

Section: Introductionmentioning

confidence: 99%

Mechanism and Control Scheme of Central Defects in Cross Wedge Rolling of Railway Vehicle Axles

Sun

Wang

Yang

2023

Metals

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Faced with a great demand for railway axles, the cross wedge rolling (CWR) process has the advantages of high efficiency and material saving, and good forming quality of axles is significant for railway transportation safety. The stress inside the railway axle of CWR was analyzed by the finite element method. It was found that the center of the rolled piece is subjected to tensile stress in transverse and axial directions and compressive stress in radial direction, making it more prone to defects. By simulating the evolution of micro voids in the center of the CWR piece, it was found that the presence of voids makes the strain around them significantly large and concentrated and the material between the voids deforms intensely. When voids expand relative to the rolled piece and the internal necking between voids is significant, void coalescence is easy to occur, and central defects are formed. The influence of process parameters on void evolution was analyzed. The scheme of detaching die was proposed to avoid central defects of the CWR piece and the optimal parameter conditions of CWR of railway axles were determined, which proved that the quality of railway axles formed with optimized parameters meets the technical requirements of railway vehicle axles.

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Rotary compression test for determination of critical value of hybrid damage criterion for railway steel EA1T

Wójcik,

Bulzak,

Lis

et al. 2024

Int J Mater Form

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The article presents and discusses the problem of determining and characterizing the cracking limits of cross-rolled specimens. The limit values were determined in accordance with the hybrid Pater criterion. For the study, the author’s test method was used, which allows the determination of the cracking moment, formed as a result of the Mannesmann effect during the compression of specimens in the channel. In order to determine the values needed to describe the cracking criterion, it was necessary to perform laboratory tests and numerical simulations of the process of compression in the channel of discs made of EA1T steel under hot forming conditions. Experimental tests were carried out for forming processes at 950 °C, 1050 °C and 1150 °C. The tested material had a disc shape with a diameter of 40 mm and a length of 20 mm, during the pressing process the diameter of the disc was reduced to a diameter of 38 mm. The increase in forming temperature caused a significant increase in the forming path until cracking occurred. Numerical tests were carried out in the finite element calculation environment Simufact.Forming 2021. The stress and strain distributions in the specimen axis were analysed during the tests, which were then used to calculate the hybrid cracking criterion limit according to Pater. After calculations according to the Pater criterion and after statistical analysis, the cracking criterion limits were obtained.

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Numerical prediction of ductile damage evolution of 40CrNiMo railway axle steel during hot cross wedge rolling

Cited by 3 publications

References 19 publications

Prediction of ductile cracking in the titanium alloy forging process

Prediction of ductile cracking in the titanium alloy forging process

Mechanism and Control Scheme of Central Defects in Cross Wedge Rolling of Railway Vehicle Axles

Rotary compression test for determination of critical value of hybrid damage criterion for railway steel EA1T

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