Prediction of the metric thread quality after axial thread rolling process on cold using of finite element methods

Kukiełka, K.; Kaldunski, Pawel; Kukiełka, L.; Kułakowska, A.; Patyk, R.

doi:10.1063/1.5092079

Cited by 4 publications

(12 citation statements)

References 8 publications

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“…The second stage of the research was to determine the impact of the integrated rotary–vibration motion of the active holder on the sample surface texture. To determine this relationship the three-level experimental plan was used [ 31 , 32 , 33 ]. The variable parameters were the rotational speeds n of the CDF machine disc and the holder n h , as well as the vibration frequency f of the active holder.…”

Section: Methodsmentioning

confidence: 99%

Investigation of the Surface Treatment Process of AISI 304 Stainless Steel by Centrifugal Disc Finishing with the Use of an Active Workpiece Holder

et al. 2022

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This article presents the results of experimental studies of the centrifugal disc finishing (CDF) process of 304 steel elements with the use of an active workpieces holder, that allows workpieces for additional rotational and oscillation movements. The main aim of the research was to evaluate the mechanism of formation of the surface texture and to assess the intensity and effectiveness of the machining process. It is shown that additional movements of the workpiece significantly affect the formation of the machining traces generated by the elementary phenomena of micro-cutting, scratching, grooving, etc. As a result, these combined and complex interactions lead to the formation of the surface topography of the workpieces. Based on the research results, it can be concluded that the use of an active workpiece holder in the CDF process allows changes in the intensity of the machining process. Moreover, the active holder allows modification of the surface smoothing process. The intensity of the treatment process depends primarily on the location of the workpiece holder in the appropriate energy area of the work charge. On the other hand, the efficiency of the workpiece surface smoothing depends on the parameters of the oscillation and rotational movements of the workpiece mounted in the active holder. The presented research results show that the use of an active holder, enabling rotation and oscillation of the workpiece, may lead to a more effective use of smoothing processes in CDF machines. The analysis of the results shows that the values of the Sdr and Sa parameters are more strongly dependent on the vibration frequency and increase with its increasing frequency. This is undoubtedly the result of the concentration of smoothing marks on the smoothed surface. However, with regard to the rotational speed of the object, this relationship is non-monotonic, and its greatest influence occurs at its intermediate values. It follows that this activity does not have a significant impact on the generation of the number of smoothing marks and the degree of their concentration. The research methodology proposed in the work allows the initial determination of the dependence of the results of the CDF process on the machining parameters, including the parameters of the active holder. This methodology can also be used for machining materials other than AISI 304 steel.

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Section: Methodsmentioning

confidence: 99%

Investigation of the Surface Treatment Process of AISI 304 Stainless Steel by Centrifugal Disc Finishing with the Use of an Active Workpiece Holder

et al. 2022

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“…As a result, for successive discrete moments of time τ 0, Δt, 2Δt, … the geometry of the body and the states of incremental displacements, displacement velocities, accelerations, strains, strain rates, and stresses are determined. The concept of incremental description has already been verified by the author and was used to describe other plastic-forming processes: cutting [36][37][38][39][40][41][42], thread rolling [15][16][17]28,29], burnishing rolling [43][44][45][46][47][48][49], drawing [50][51][52], grinding with a single abrasive grain [53], calculating the fatigue strength of products [54][55][56], and diamond sliding burnishing [56].…”

Section: The Concept Of Incremental Descriptionmentioning

confidence: 99%

“…In order to create plane states of displacements and strain in the workpiece, as well as a spatial state of stresses, the Author used an innovative method of thread rolling (Figure 1c) [15,16,17,19]. This method is based on the fact that the head basket (1) is driven d-f): (a)-stationary basket of the head and rollers driven and a rotating non-driven workpiece that moves axially relative to the head; (b)-stationary head basket, rotating and non-driven rollers and rotating and driven workpiece; the head with the rollers moves axially relative to the workpiece; (c)-stationary object, rotating and driven basket of the head and rotating and non-powered rollers; the head with the rollers moves axially relative to the workpiece: 1-head basket, 2-rollers, 3-workpiece, v r -rolling speed, v h -peripheral speed of the head.…”

Section: Introductionmentioning

confidence: 99%

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Application of the FEM Method to Modeling and Analysis of the Cold Thread Rolling Process—Part 1: Conditions for Ensuring a Plane State of Deformations

Kukiełka

2023

Materials

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The article concerns the application of the FEM method for the prediction of stress and deformation states in a workpiece during the thread rolling process (TR). The analysis covered a new kinematic variant of the TR process in which the basket of the head rotates and is torque-driven, while the workpiece is stationary and the head with the rollers moves axially relative to the workpiece. The TR process was considered as a geometrical and physical non-linear initial and boundary problem with non-linear, moving, and variable in time and space boundary conditions. The boundary conditions in the contact areas of the tool with the workpiece were unknown. An updated Lagrange (UL) description was used to describe the physical phenomena at a typical incremental step. The states of strain and strain rate were described by non-linear relationships without linearization. New discrete systems of motion and deformation equations of the object in the TR were introduced, which take into account the change in the stiffness of the system during the TR process. This equation was solved by the central differences method (explicit). The material parameters were estimated during tensile tests to determine the characteristics of the C45 steel, and a new semi-empirical method was used to determine the relationship yield stress, effective true strain, and effective true strain rate in the thread rolling process. A modified Cowper–Symonds material model was also used to model the displacement process of the wedge on an elastic/visco-plastic body reflecting the TR process. A non-linear dependency of material hardening module depending on strain and strain rate was introduced. To confirm the plane state of deformation and spatial state of stress, an experimental investigation was carried out. The computer models were validated, and a good convergence of the results was obtained. Applications in the ANSYS/LS-Dyna program were developed to simulate the TR process. The developed applications enable a comprehensive time analysis of the states of displacement, strain, and stress occurring in an object consisting of a workpiece (shaft) and a tool (roller) for the case of a plane strain state and a spatial stress state. Exemplary results of numerical analyzes are presented to explain the influence of the friction coefficient on the condition of the thread quality, and the state of deformations and stresses were shown.

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“…Yamanaka S [10] studied the stress distribution during the roll forming of metallic glass materials and revealed the mechanism of plastic deformation during the rolling process. Krzysztof Kukielka [11] discussed the possibility of predicting the quality of cold rolled threads using numerical methods and verified that the friction coefficient significantly affects the thread profile and stress-strain behavior. 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.…”

Section: Introductionmentioning

confidence: 98%

Orthogonal Simulation Optimization of GH4169 Bolt Thread Rolling Process Parameters

Zheng

et al. 2023

Preprint

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GH4169 alloy is a precipitation-strengthened nickel-chromium-iron-based superalloy, widely known for its challenging machinability in thread rolling processes. The optimization of bolt thread rolling process parameters holds significant research importance, particularly for ensuring batch stability in the production of high-end aerospace fasteners. GH4169 bolts are prone to metallographic folding in the crest and root areas after thread rolling, necessitating the urgent need to optimize the thread rolling process parameters. In this study, a finite element simulation model of the GH4169 bolt thread rolling process was established using ABAQUS software. The thread rolling process parameters, including the feed speed of the thread rolling die, feed speed of the thread rolling die, and initial temperature of the workpiece, were optimized through orthogonal simulation. It was found that, while meeting the technical requirements, a smaller thread forming force yielded better results. Range analysis and variance analysis were conducted on the simulation results to determine the influence trend and significance degree of the thread rolling process parameters on the thread forming force. The research findings of this study can effectively guide actual production processes and significantly reduce exploration time in the GH4169 bolt thread rolling process for enterprises.

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Prediction of the metric thread quality after axial thread rolling process on cold using of finite element methods

Cited by 4 publications

References 8 publications

Investigation of the Surface Treatment Process of AISI 304 Stainless Steel by Centrifugal Disc Finishing with the Use of an Active Workpiece Holder

Investigation of the Surface Treatment Process of AISI 304 Stainless Steel by Centrifugal Disc Finishing with the Use of an Active Workpiece Holder

Application of the FEM Method to Modeling and Analysis of the Cold Thread Rolling Process—Part 1: Conditions for Ensuring a Plane State of Deformations

Orthogonal Simulation Optimization of GH4169 Bolt Thread Rolling Process Parameters

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