Experimental and numerical study of the effect of rolling parameters on shaft deformation during the longitudinal rolling process

2018 ◽  
Author(s):  
Marek Kowalik ◽  
Tomasz Trzepiecinski
Keyword(s):  
Numerical Study ◽  
Rolling Process ◽  
Longitudinal Rolling ◽  
Shaft Deformation

Numerical simulation of slab deformation process with different reduction values in vertical rolls of mill 2000 roughing stands

2021 ◽  
Vol 77 (6) ◽  
pp. 675-681
Author(s):  
N. L. Bolobanova ◽  
E. A. Garber
Keyword(s):  
Process Model ◽  
Surface Defects ◽  
Numerical Study ◽  
Rolling Process ◽  
Rolled Stock ◽  
Metal Consumption ◽  
Wide Face ◽  
Total Reduction ◽  
Hot Rolling Mill ◽  
Deform 3D

Perfection of rolled stock production processes at continuous wide-strip hot rolling mill (CWHRM) aimed at minimization of metal consumption, is an effective mean to decrease its cost. In the process of slabs rolling at CWHRM, the metal consumption is stipulated first of all by complicated workpiece forming in roughing stands during consecutive reduction by vertical and horizontal rolls. Results of the numerical study of slab deformation with different values of reduction in vertical rolls of roughing stands of mill 2000 are presented. The implementation of rolling process model based on application of DEFORM-3D program of finiteelement analysis described for evaluation of metal shifting from the edges of slab in the direction of the middle of the width. The convergence of the simulation results with the measurements data of workpiece forming during roughing rolling at Severstal mill 2000 was experimentally confirmed. It was found that an increase of reduction in vertical rolls has no significant effect on the metal shifting from a narrow edge to a wide one. Increase the total reduction in vertical rolls leads to an unfavorable stress-strain state of the edge region and the Cockcroft–Latham criterion rises by 20–30%. It was proposed to reduce the total reduction in the vertical rolls of the roughing stands of mill 2000 down to 40–50 mm. It was shown that increase of time of slab moving from the heating furnace to the scale breaker causes growth the Cockcroft-Latham criterion and does not affect the amount of metal shifting from a narrow face to a wide one. The proposed method of simulation the process of slab deformation in the roughing group of the mill 2000 proved by results of industrial rolling can to be used for further study of the effect of rolls profiling and forming of surface defects with the provision of minimal metal shifting onto a wide face.

scholarly journals Skew Rolling of Rods from Scrap Rail Heads

Materials ◽  
2019 ◽  
Vol 12 (18) ◽  
pp. 2970 ◽  
Author(s):  
Tomczak ◽  
Pater ◽  
Bulzak
Keyword(s):  
Experimental Tests ◽  
Rolling Process ◽  
Industrial Applications ◽  
Experimental Investigations ◽  
Longitudinal Rolling ◽  
Rolling Mills ◽  
Second Stage ◽  
New Process ◽  
Skew Rolling ◽  
Theoretical Considerations

This paper presents the results of theoretical and experimental investigations of a new process of rolling rods from scrap rail heads. First, the industrial applications of scrap railway rails and methods of their recycling are discussed, and then the concept of two-stage rolling of rods from heads cut off from scrap rails is proposed. In the first stage of the process, a rail head preform was rolled in a hexagonal pass of a longitudinal rolling mill. Then in the second stage, the hexagonal bar was skew rolled into a rod in a helical roll pass. Theoretical considerations were based on finite element numerical modelling. The rolling process was simulated under 3D deformation using Forge NxT v.1.1 software developed by Transvalor Company. Calculations were carried out to determine the material flow kinematics, strength, and thermal parameters of the process and to identify the phenomena that might constrain its implementation. The numerical results were verified in experimental tests, during which preforms and rods were formed from scrap rail heads. The tests were conducted in longitudinal and skew rolling mills. The results indicate that rods can be effectively formed from scrap rail heads in just two steps. Rods obtained using the proposed method can be used as full-featured, semifinished products for the manufacture of various types of machine parts.

A Numerical Study of Solder Paste Rolling Process for PCB Printing

2018 ◽  
Author(s):  
Ricardo F. Oliveira ◽  
Nelson Rodrigues ◽  
José Carlos Teixeira ◽  
Duarte Santos ◽  
Delfim Soares ◽  
...  
Keyword(s):  
Numerical Study ◽  
Flow Simulation ◽  
Rolling Process ◽  
Production Costs ◽  
Process Efficiency ◽  
Solder Paste ◽  
Filling Process ◽  
Newtonian Viscosity ◽  
Air Interface ◽  
Increasing Demand

The increasing demand for electronic devices associated with the increasing competitiveness between enterprises, pushes towards process automation to decrease production costs. The reflow soldering has proven to be effective in this regard. This is composed by a series of steps or processes, such as: (a) stencil printing, (b) component placement and (c) reflow oven soldering. Each process has its specific traits that contribute to the overall process efficiency. The present study is directed towards process (a), which includes the rolling of the solder paste over the stencil surface, followed by the subsequent filling of the stencil apertures. Several parameters influence the solder paste behaviour and thus the effectiveness of the rolling process. This work focuses on the solder paste non-Newtonian viscosity properties, with the solder paste presenting a thixotropic behaviour, necessary for the filling of the stencil apertures. Although the increase in the squeegee velocity causes extra shear in the solder paste and consequently lower viscosity, the excess of velocity may cause defects in the aperture filling process. In addition, during the rolling process, air may become entrapped in the solder paste. The complexity of this process is addressed by numerical simulation, in particular, using the work-package ANSYS to study the solder paste progress, during the rolling process, as well as the parameters influencing it. The fluid flow simulation is solved using the solver FLUENT®, a simplified 2D domain with real case dimensions, a transient prediction of the viscosity, which is a function of the solder paste solicitation, and finally by using the Volume of Fluid (VOF) method to track the solder-air interface boundary. Dynamic meshing methods are also employed to replicate the movement of the squeegee wall, in its task to push the solder paste tumble over the stencil. This study enlightens the role played by the printing velocity in the stencil aperture filling, a logarithm correlation can be found between them. It was found that lower print velocities provide better results than higher speeds. It was observed that the back tip of the squeegee blade causes a partial removal of the solder paste from the aperture, which is higher for faster print processes. An analysis of the filling process over time concluded that, independently of the printing velocity, 90% of the filling occurs in the first quarter of the process.

Analysis of Asymmetrical Rolling Process of Multilayer Plates

2010 ◽  
Vol 165 ◽  
pp. 348-352 ◽  
Author(s):  
Robert Skoblik ◽  
Dariusz Rydz ◽  
Grzegorz Stradomski
Keyword(s):  
Finite Element Method ◽  
Numerical Modeling ◽  
Aluminium Alloys ◽  
Explosive Welding ◽  
Numerical Study ◽  
Rolling Process ◽  
Pure Aluminium ◽  
Asymmetrical Rolling ◽  
Explosive Cladding ◽  
Welding Technology

. Literature provides three basic methods of explosive cladding, developed by Darenport and Person. Welding trials were performed in two- and three-layer arrangements, where in the second case, copper plates were welded with plates made from aluminium alloys with an interlayer of pure aluminium. Explosive welding technology does not always allow for joining of sheets of specific thicknesses. In order to obtain such thickness, they need to be rolled. The paper presents results of numerical study of asymmetrical rolling process of multilayer plates M1E-Al99.8-AlMg5. Numerical modeling of rolling of multilayer plates was realized by means of Forge 2D program that is based on finite element method. Obtained research results enabled to elucidate the process of rolling of multilayer plates.

scholarly journals Numerical study of rolling process on the plastic strain distribution in wire + arc additive manufactured Ti-6Al-4V

2019 ◽  
Author(s):  
M. Abbaszadeh ◽  
J. Hönnige ◽  
F. Martina ◽  
N. Kashaev ◽  
S. W. Williams ◽  
...  
Keyword(s):  
Plastic Strain ◽  
Strain Distribution ◽  
Numerical Study ◽  
Rolling Process ◽  
Plastic Strain Distribution

Experimental and Numerical Study of Emulsion Lubricated Strip Rolling

2005 ◽  
Author(s):  
P. B. Kosasih ◽  
A. K. Tieu
Keyword(s):  
Film Thickness ◽  
Numerical Study ◽  
Rolling Process ◽  
Work Zone ◽  
Contact Ratio ◽  
Strip Rolling ◽  
Two Phase ◽  
Oil Concentration ◽  
Mixed Film ◽  
Inlet Zone

An experimental and numerical study of cold rolling lubricated by O/W emulsion has been carried out. The experimental measurements are compared to the computed results from the numerical scheme developed by the authors. The scheme, which is based on two-phase lubricant model, is able to calculate oil concentration at any point within the inlet zone and work zone, rolling pressure, film thickness, and fractional contact ratio associated with strip rolling under mixed film lubrication at different rolling speed. The study encompassed extensive mixed film regime for speed, S ranges from 10−5 to 10−1, and supply oil concentration level λds ranges from 1% to 10%, and oil droplet size ranges from Ds from 5 to 20. The numerical results show the occurrence of moderate oil concentration increase in the inlet zone followed by a sharp one at the beginning of the work zone. The effect of the concentration process is predominantly seen in the film thickness and the lubricant pressure whilst its effect on the total pressure is less pronounced. The analysis of the results suggests that it is possible to lower the emulsion oil concentration without detrimental effects on the rolling process and indeed use this principle to control the outlet lubricant film thickness.

scholarly journals Numerical And Experimental Study On Producing Aluminum Alloy 6061 Shafts By Cross Wedge Rolling Using A Universal Rolling Mill

2015 ◽  
Vol 60 (2) ◽  
pp. 801-807 ◽  
Author(s):  
A. Tofil ◽  
J. Tomczak ◽  
T. Bulzak
Keyword(s):  
Aluminum Alloy ◽  
Rolling Mill ◽  
Metal Flow ◽  
Rolling Process ◽  
Simulation Software ◽  
Cross Wedge Rolling ◽  
Longitudinal Rolling ◽  
Forming Simulation ◽  
Aluminum Alloy 6061 ◽  
Alloy 6061

Abstract The paper presents a selection of numerical and theoretical results of the cross wedge rolling process for producing stepped shafts made of aluminum alloy 6061. The numerical modeling was performed using the FEM-based Simufact Forming simulation software. In the simulations, we examined the kinematics of metal flow and determined the distribution patterns of effective strains, temperatures, axial stresses and the Cockroft-Latham damage criterion. Variations in the rolling forces were determined, too. The numerical results were verified experimentally using a universal rolling mill designed and constructed by the present authors. This machine can be used to perform such processes as cross wedge rolling, longitudinal rolling and round bar cropping. During the experiments, we examined process stability and finished product geometry and recorded the torques. The experimental results confirm that axisymmetric aluminum alloy shafts can be produced by cross wedge rolling with two rolls. Last but not least, the experiments served to evaluate the technological potential of the rolling mill used.

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