Physical Modeling of Cross Wedge Rolling Limitations

Wójcik, Łukasz; Pater, Z.; Bulzak, Tomasz; Tomczak, J.

doi:10.3390/ma13040867

Cited by 11 publications

(12 citation statements)

References 21 publications

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“…Additionally, many researchers have stressed the importance of calculating strain-hardening coefficients such as a strength coefficient, c, and a strain-hardening exponent, n. They are particularly essential when selecting heat treatment technological parameters or elaborating metal forming technology for steel [22,23], aluminium alloys [24,25], magnesium alloys [26,27], pure copper [28], powder metallurgy materials [29,30], or plasticine [31,32], or even MMC (metal matrix composite) materials [33,34]. Therefore, this paper investigates the effect of annealing on the strain-hardening parameters, and the c and n coefficients are determined and can be used in numerical simulations and experimental tests of 42CrMo4 steel components dedicated for metal forming [35,36].…”

Section: Introductionmentioning

confidence: 99%

Effect of Annealing Time and Temperature Parameters on the Microstructure, Hardness, and Strain-Hardening Coefficients of 42CrMo4 Steel

et al. 2020

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The study presents the effect of annealing process parameters on the microstructure, hardness, and strain-hardening coefficients, that is, the strength coefficient c and the strain-hardening exponent n, of 42CrMo4 steel. Seven selected annealing time–temperature schemes are examined for superior steel formability in cold metal forming conditions. The c and n coefficients are first determined in experimental upsetting of annealed samples and then used in FEM (finite element method) simulations of the upsetting process. The results demonstrate that the strain-hardening coefficients (c and n) depend on the employed annealing scheme. Compared with the as-received sample, the annealing process reduces the true stress and effectively decrease the hardness of 42CrMo4 steel; improves microstructural spheroidization; and, consequently, facilitates deformability of this material. The annealing schemes, relying on heating the material to 750 °C and its subsequent slow cooling, lead to the highest decrease in hardness ranging from 162 to 168 HV. The results obtained with the SEM-EDS (scanning electron microscopy-energy dispersive spectrometer), LOM (light optical microscopy), and XRD (X-ray diffraction) methods lead to the conclusion that the employed heat treatment schemes cause the initial ferritic-pearlitic microstructure to develop granular and semi-lamellar precipitation of cementite enriched with Mo and Cr in the ferrite matrix. In addition, the annealing process affects the growth of α-Fe grains. The highest cold hardening rate, and thus formability, is obtained for the annealing scheme producing the lowest hardness. The results of FEM simulations are positively validated by experimental results. The obtained results are crucial for further numerical simulations and experimental research connected with developing new cold metal forming methods for producing parts made of 42CrMo4 steel.

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Section: Introductionmentioning

confidence: 99%

Effect of Annealing Time and Temperature Parameters on the Microstructure, Hardness, and Strain-Hardening Coefficients of 42CrMo4 Steel

et al. 2020

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“…Analogue modelling using plasticine was used as the method to visualise the flow. In other areas plasticine has been used for analysis of the plastic deformation processes [27][28][29]. Use of a soft material like plasticine rather than aluminium or some other metal allowed the tools to be manufactured with 3D printing.…”

Section: Methodsmentioning

confidence: 99%

3D-Printed Tool Shoulder Design for the Analogue Modelling of Bobbin Friction Stir Weld Joint Quality

Tamadon

Pons

Chakradhar

et al. 2021

Advances in Materials Science

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A variety of tool shoulder designs comprising three families i.e. blade, spiral and circular shaped scrolls, were produced to improve the material flow and restrictions to avoid the tunnel void. The bobbin tools were manufactured by 3D printing additive manufacturing technology using solid filament. The butt weld joint was produced by each tool using plasticine as the workpiece material. The apparent surface features and bi-colour cross-sections provided a physical flow comparison among the shoulder designs. For the bobbin friction stir welding (BFSW), the tool shoulder with a three-spiral design produced the most stability with the best combination of the flow patterns on surface and cross-sections. The circular family tools showed a suitable intermixing on the surface pattern, while the blade scrolls showed better flow features within the cross-sections. The flow-driven effect of the shoulder features of the bobbin-tool design (inscribed grooves) was replicated by the 3D-printed tools and the analogue modelling of the weld samples. Similar flow patterns were achieved by dissimilar aluminium-copper weld, validating the accuracy of the analogue plasticine for the flow visualization of the bobbin friction stir welding.

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“…1 The principle of material displacement during CWR, own figure according to [12] with a lower forming angle and a higher wedge angle . The probability is additionally influenced by the amount of non-metallic inclusions, low material cohesion due to material fatigue, high temperatures and cyclically varying compressive and tensile stresses [10,[16][17][18][19].…”

Section: Hot Forming With the Cwr Processmentioning

confidence: 99%

“…The microstructure of the different specimens and layers can be seen in Figs. 16,17,18,19 The microstructure of the base material depends on the cooling method. Cooling in water leads to a high cooling rate.…”

Section: Microhardness and Microstructurementioning

confidence: 99%

Investigation of the material combination 20MnCr5 and X45CrSi9-3 in the Tailored Forming of shafts with bearing seats

Budde

Biester

Merkel

et al. 2022

Prod. Eng. Res. Devel.

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The Tailored Forming process chain is used to manufacture hybrid components and consists of a joining process or Additive Manufacturing for various materials (e.g. deposition welding), subsequent hot forming, machining and heat treatment. In this way, components can be produced with materials adapted to the load case. For this paper, hybrid shafts are produced by deposition welding of a cladding made of X45CrSi9-3 onto a workpiece made from 20MnCr5. The hybrid shafts are then formed by means of cross-wedge rolling. It is investigated, how the thickness of the cladding and the type of cooling after hot forming (in air or in water) affect the properties of the cladding. The hybrid shafts are formed without layer separation. However, slight core loosening occurres in the area of the bearing seat due to the Mannesmann effect. The microhardness of the cladding is only slightly effected by the cooling strategy, while the microhardness of the base material is significantly higher in water cooled shafts. The microstructure of the cladding after both cooling strategies consists mainly of martensite. In the base material, air cooling results in a mainly ferritic microstructure with grains of ferrite-pearlite. Quenching in water results in a microstructure containing mainly martensite.

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Physical Modeling of Cross Wedge Rolling Limitations

Cited by 11 publications

References 21 publications

Effect of Annealing Time and Temperature Parameters on the Microstructure, Hardness, and Strain-Hardening Coefficients of 42CrMo4 Steel

Effect of Annealing Time and Temperature Parameters on the Microstructure, Hardness, and Strain-Hardening Coefficients of 42CrMo4 Steel

3D-Printed Tool Shoulder Design for the Analogue Modelling of Bobbin Friction Stir Weld Joint Quality

Investigation of the material combination 20MnCr5 and X45CrSi9-3 in the Tailored Forming of shafts with bearing seats

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