Stamping by Rolling Blanks Using Advanced Energy-Efficient Induction Heating

Abstract

The article presents the results of development and research of technological schemes of cold forming by rolling (CFR) of blanks. Expansion of the technological capabilities of the processes of COP and improving the quality of products is based on the control of active friction forces and deformability of the processed metals. The main limiting factors in the application of SHO processes are insufficient ductility of metals, which causes the risk of destruction of workpieces, as well as relatively large deformation forces that cause unfavorable operating conditions of the rolling bearing unit. The solution of these problems is facilitated by the transition to hot SHO. However, the problems of manufacturing by the hot SHO method of products from tubular and solid cylindrical billets have been little studied to date. An effective process of billets heating is induction heating, but its application is characterized by relatively low efficiency. In this work, it is recommended to use new materials and technology for the manufacture of induction heaters for the implementation of hot SHO, which open up opportunities for improving induction heating equipment for industrial applications. The use of new generation induction heaters to replace other heating methods in metalworking has significant advantages: higher efficiency; less scattered magnetic fields; less complexity of the coil design; increased geometric freedom; no water cooling is required. In order to study the hot SHO, devices for rolling billets with conical and cylindrical rolls were designed and manufactured. Physical modeling of hot SHO by using solid cylindrical lead billets was carried out. It is experimentally proved that the process of hot SHO allows to achieve significant degrees of deformation even at unfavorable stress-strain state and insignificant power of the equipment. Thus, the process of induction heating of blanks can be quite effective when processing them by hot SHO.