scholarly journals A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3084
Author(s):  
Zbigniew Pater
Keyword(s):  
Comparative Analysis ◽  
Effective Strain ◽  
Experimental Tests ◽  
Rolling Process ◽  
Simulation Software ◽  
Compression Technique ◽  
Rolling Mills ◽  
University Of Technology ◽  
Basic Force ◽  
Skew Rolling

The paper presents a comparative analysis of skew rolling in 3- and 4-roll CNC rolling mills. The analysis is performed using the FEM-based commercial simulation software Simufact.Forming. The formation of both solid and hollow railway axles is analyzed. Distributions of effective strain, temperature and damage criterion in rolled axles are determined, and loads and torques acting on the tools during rolling are estimated. An innovative concept of calibrating hollow axles by the rotary compression technique developed at the Lublin University of Technology is presented. Experimental tests of rolling solid axles in a 3-roll rolling mill (in a scale of 1:5) are performed, and basic force parameters of the rolling process are measured. Numerical and experimental loads and torques show a high agreement in terms of both quality and quantity.

scholarly journals The Effect of Process Parameters in Helical Rolling of Balls on the Quality of Products and the Forming Process

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2125 ◽  
Author(s):  
Janusz Tomczak ◽  
Zbigniew Pater ◽  
Tomasz Bulzak
Keyword(s):  
Metal Flow ◽  
Experimental Tests ◽  
Rolling Process ◽  
Helical Rolling ◽  
Forming Process ◽  
University Of Technology ◽  
Quality Of Products ◽  
Skew Rolling

This paper presents selected numerical and experimental results of a skew rolling process for producing balls using helical tools. The study investigates the effect of the billet’s initial temperature on the quality of produced balls and the rolling process itself. In addition, the effect of billet diameter on the quality of produced balls is investigated. Experimental tests were performed using a helical rolling mill available at the Lublin University of Technology. The experiments consisted of rolling 40 mm diameter balls with the use of two helical tools. To determine optimal rolling parameters ensuring the highest quality of produced balls, numerical modelling was performed using the finite element method in the Forge software. The numerical analysis involved the determination of metal flow kinematics, temperature and damage criterion distributions, as well as the measurement of variations in the force parameters. The results demonstrate that the highest quality balls are produced from billet preheated to approximately 1000 °C.

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.

scholarly journals Numerical Analysis of the Skew Rolling Process for Rail Axles

2015 ◽  
Vol 60 (1) ◽  
pp. 415-418 ◽  
Author(s):  
Z. Pater ◽  
J. Tomczak ◽  
T. Bulzak
Keyword(s):  
Numerical Modeling ◽  
Effective Strain ◽  
Translational Motion ◽  
Rolling Process ◽  
Simulation Software ◽  
Maximum Diameter ◽  
Cross Sectional ◽  
Rolling Method ◽  
Skew Rolling

Abstract The paper describes a new method for producing stepped rail axles. The method is based on the skew rolling process. With this method, the product is formed by three tapered rolls located every 120° on the perimeter of the billet. Positioned askew to the centerline of the billet, the rolls rotate in the same direction and with the same velocity. At the same time, they get closer together or go apart depending on the desired cross sectional reduction of an axle step. In addition, the workpiece is shifted lengthwise relative to the rolls by the translational motion of the workpiece-holding chuck. In order to verify the designed method for producing rail axles, a series of numerical simulations were performed using the Simufact. Forming v.12 simulation software. The numerical modeling enabled the determination of maps of the effective strain and temperature in the finished product as well as variations in the loads and torques during rolling. The numerical results unambiguously confirm that the skew rolling method can be applied to form parts of considerable dimensions (the modeled axles had a length of 2146 mm and their maximum diameter was 202 mm).

scholarly journals The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 764
Author(s):  
Jarosław Bartnicki ◽  
Yingxiang Xia ◽  
Xuedao Shu
Keyword(s):  
Cross Section ◽  
Rolling Mill ◽  
Metal Flow ◽  
Experimental Tests ◽  
Rolling Process ◽  
Numerical Control ◽  
Technological Parameters ◽  
Flow Mechanisms ◽  
The Individual ◽  
Skew Rolling

The paper presents chosen aspects of the skew rolling process of hollow stepped products with the use of a skew rolling mill designed and manufactured at the Lublin University of Technology. This machine is characterized by the numerical control of spacing between the working rolls and the sequence of the gripper axial movement, which allows for the individual programming of the obtained shapes of parts such as stepped axles and shafts. The length of these zones and the values of possibly realizable cross-section reduction and obtained outlines are the subject of this research paper. The chosen results regarding the influence of the technological parameters used on the course of the process are shown in the present study. Numerical modelling using the finite element method in Simufact Forming, as well as the results of experimental tests performed in a skew rolling mill, were applied in the conducted research. The work takes into account the influence of cross-section reduction of the hollow parts and the feed rate per rotation on the metal flow mechanisms in the skew rolling process. The presented results concern the obtained dimensional deviations and changes in the wall thickness determining the proper choice of technological parameters for hollow parts formed by the skew rolling method. Knowledge about the cause of the occurrence of these limitations is very important for the development of this technology and the choice of the process parameters.

Influence of the Deformation Method on the Microstructure Changes in AZ31 Magnesium Alloy Round Rods Obtained by the Rolling Process

2016 ◽  
Vol 716 ◽  
pp. 864-870
Author(s):  
Andrzej Stefanik ◽  
Piotr Szota ◽  
Sebastian Mróz ◽  
Teresa Bajor ◽  
Sonia Boczkal
Keyword(s):  
Magnesium Alloy ◽  
Numerical Modelling ◽  
Rolling Mill ◽  
Laboratory Tests ◽  
Effective Strain ◽  
Rolling Process ◽  
Az31 Magnesium Alloy ◽  
Deformation Method ◽  
Microstructure Changes ◽  
Skew Rolling

This paper presents the research results of the microstructure changes of the round rods of AZ31 magnesium alloy in the hot rolling processes. The rolling was conducted in duo mill and a three-high skew rolling mill. Numerical modelling of the AZ31 magnesium alloy round rods rolling process was conducted using a computer program Forge 2011®. The verification of the results of numerical modelling was carried out during laboratory tests in a two-high rolling mill D150 and a three-high skew rolling mill RSP 40/14. Distributions of the total effective strain and temperature during AZ31 rods rolling process were determined on the basis of the theoretical analysis. Microstructure and texture changes during both analysed processes were studied.

scholarly journals A Comparative Analysis of the Physical Modelling of Two Methods of Balls Separation

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7126
Author(s):  
Łukasz Wójcik ◽  
Zbigniew Pater ◽  
Tomasz Bulzak ◽  
Janusz Tomczak ◽  
Konrad Lis
Keyword(s):  
Comparative Analysis ◽  
Physical Modelling ◽  
Rolling Process ◽  
Model Material ◽  
Physical Analysis ◽  
Real Process ◽  
Radial Forces ◽  
3D Printed ◽  
Torque Values ◽  
Skew Rolling

The article presents the results of model tests with which a comparative analysis of two methods of ball separation during the skew rolling process was carried out. A verification of the results obtained in the physical modelling process with the results obtained in the real process of skew ball rolling was also carried out. During the physical modelling, the effect of changing the ball separation method on the quality of the products obtained, variations in maximum torque values and maximum radial forces were analyzed. In the case of real tests, the results were verified with the results of physical modelling, in which the surface quality and torque values for one of the tool sets were compared. Physical modelling was used to verify the differences between the two methods of ball separation. Commercial plasticine based on synthetic wax from the manufacturer PRIMO was used as a model material for physical analysis. The plasticine used for testing was cooled to 0 °C and the cooling process took 24 h. The tools used for the physical modelling were 3D printed and the material used was ABS. The method of physical modelling using plasticine as a model material allows for a correct analysis of hot metal forming processes.

scholarly journals Numerical Analysis of a Skew Rolling Process for Producing a Stepped Hollow Shaft Made of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 61 (2) ◽  
pp. 677-682 ◽  
Author(s):  
Z. Pater ◽  
T. Bulzak ◽  
J. Tomczak
Keyword(s):  
Numerical Analysis ◽  
Thickness Distribution ◽  
Effective Strain ◽  
Rolling Process ◽  
Forming Process ◽  
Hollow Shaft ◽  
Wall Thickness Distribution ◽  
Light Trucks ◽  
Titanium Alloy Ti6al4v ◽  
Skew Rolling

Abstract The paper describes a rolling process for a hollow Ti6Al4V alloy shaft used in driving systems of light trucks. The shaft is formed by skew rolling using three tapered rolls. The principle of this forming process was discussed stressing its universality due to the potential of applying it for forming various products by one set of rolls. The numerical analysis results (product shape progression in rolling, wall thickness distribution, effective strain, temperature and variations in loads and torques) confirm that the proposed technique can be used for producing hollow long shafts.

scholarly journals Theoretical And Experimental Analysis Of Aluminium Bars Rolling Process In Three-High Skew Rolling Mill

2015 ◽  
Vol 60 (2) ◽  
pp. 809-813 ◽  
Author(s):  
A. Stefanik ◽  
A. Morel ◽  
S. Mróz ◽  
P. Szota
Keyword(s):  
Rolling Mill ◽  
Rolling Process ◽  
Theoretical Research ◽  
Rolling Mills ◽  
Good Surface ◽  
Experimental Rolling ◽  
Deformation Stress ◽  
Deformable Materials ◽  
Roll Gap ◽  
Skew Rolling

Abstract Technology of round bars rolling on a three-high skew rolling mills allows rolling of standard materials such as steel and aluminum, as well as new materials, especially hard deformable materials. The paper presents the results of theoretical and experimental rolling process of aluminum bars with a diameter of 20 mm. As the stock round bars with a diameter of 25 mm made of aluminum grade 1050A and aluminum alloy grade 2017A were used. The rolling process of aluminum bars has been carried out in a single pass. The numerical analysis was carried out by using computer program Forge2011®. On the basis of theoretical research it has been determined the state of deformation, stress and temperature distribution during rolling of aluminum bars. In addition, the results of theoretical research allowed to determine the schema of the metal plastic flow in the roll gap. Verification of the theoretical research was carried out during the rolling of aluminum bars on the RSP 40/14 laboratory three-high skew rolling mill. From the finished bars were taken the samples to set the shape and compared with the results of theoretical research. Finished aluminum round bars were characterized by low ovality and good surface quality.

Rigid-Plastic Finite Element Analysis of Cross Wedge Rolling

2010 ◽  
Vol 654-656 ◽  
pp. 1610-1613
Author(s):  
Dyi Cheng Chen ◽  
Ci Syong You ◽  
Gua Nying Lai ◽  
Syue Cheng Ji
Keyword(s):  
Finite Element ◽  
Effective Strain ◽  
Rolling Process ◽  
Simulation Software ◽  
Cross Wedge Rolling ◽  
Rigid Plastic ◽  
Element Analysis ◽  
Finite Element Software ◽  
Plastic Deformation Behavior ◽  
Major Factors

In the cross wedge rolling process, many factors must be controlled to obtain the required plastic strain and desired tolerance values. The major factors include the wedge relative velocity, the forming angle, the spreading angle, and sectional reduction. This paper uses rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it is processed for cross wedge rolling. This study analyzes the effective strain, the effective stress, and the X-axial load distribution of the workpiece under various rolling conditions. Furthermore, using simulation software to analyze the changes to the microstructure by the rolling process, this study presents analytical results that confirm the suitability of the current finite element software for cross wedge rolling.

scholarly journals FEM Analysis of Loads and Torque in a Skew Rolling Process for Producing Axisymmetric Parts

2017 ◽  
Vol 62 (1) ◽  
pp. 85-90 ◽  
Author(s):  
Z. Pater
Keyword(s):  
Metal Forming ◽  
Axial Load ◽  
Fem Analysis ◽  
Rolling Process ◽  
The Finite Element Method ◽  
Skew Angle ◽  
Billet Temperature ◽  
University Of Technology ◽  
Forming Angle ◽  
Skew Rolling

Abstract Skew rolling is a metal forming technique which can be used for producing stepped axles and shafts. This paper investigates seventeen cases of rolling at varying process parameters by the finite element method. As a result, it is possible to determine the effect of the forming angle α, skew angle Θ, linear velocity of the chuck, v, billet temperature, T, rotational speed of the rolls, n, reduction ratio, δ and friction factor, m, on axial load (acting on the chuck), radial load (acting on the roll in the radial direction) and torque. The results will be used when designing a laboratory stand for skew rolling which will be constructed at the Lublin University of Technology.

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