FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft
The paper presents the results of numerical modeling of a cross-wedge rolling process for producing a stepped shaft. The modeling was performed with commercial software Forge NxT 1.1 using the finite element method. The numerical analysis enabled the determination of changes in the shape of the work...
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Pater, Z. Tomczak, J. Bulzak, T. 2020-12-16T16:01:56Z 2020-12-16T16:01:56Z 2017 FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft / Z. Pater, J. Tomczak, T. Bulzak // Проблемы прочности. — 2017. — № 4. — С. 43-53. — Бібліогр.: 81 назв. — англ. 0556-171X https://nasplib.isofts.kiev.ua/handle/123456789/173687 539.4 The paper presents the results of numerical modeling of a cross-wedge rolling process for producing a stepped shaft. The modeling was performed with commercial software Forge NxT 1.1 using the finite element method. The numerical analysis enabled the determination of changes in the shape of the workpiece, effective strain, damage function and temperature distributions, as well as variations in the forces and torque acting on the tool. The numerical results demonstrate that personal computers can today be used to model even the most difficult cases of the cross-wedge rolling process, in which complex shapes of the tools and thermal phenomena occurring during the forming process have to be taken into consideration Представлены результаты численного моделирования процесса поперечно-клиновой прокатки для изготовления ступенчатого вала. Моделирование выполнялось на базе коммерческой программы Forge NxT 1.1 с использованием метода конечных элементов. Численное решение позволило определить изменения формы изделия, эффективной деформации, функции повреждаемости и распределения температур, а также сил и крутящих моментов, действующих на вал. Показано, что для моделирования даже наиболее трудных случаев процесса ПКП, когда необходимо учитывать сложные конфигурации изделий и тепловые явления, возникающие в процессе формоизменения, могут использоваться персональные компьютеры. This scientific work was funded from the research and education (statutory activity) fund granted by the Polish Ministry of Science and Higher Education to the Faculty of Mechanical Engineering of the Lublin University of Technology. en Інститут проблем міцності ім. Г.С. Писаренко НАН України Проблемы прочности Научно-технический раздел FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft Моделирование процесса поперечно-клиновой прокатки для изготовления ступенчатого вала методом конечных элементов Article published earlier |
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| title |
FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft |
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FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft Pater, Z. Tomczak, J. Bulzak, T. Научно-технический раздел |
| title_short |
FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft |
| title_full |
FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft |
| title_fullStr |
FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft |
| title_full_unstemmed |
FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft |
| title_sort |
fem simulation of the cross-wedge rolling process for a stepped shaft |
| author |
Pater, Z. Tomczak, J. Bulzak, T. |
| author_facet |
Pater, Z. Tomczak, J. Bulzak, T. |
| topic |
Научно-технический раздел |
| topic_facet |
Научно-технический раздел |
| publishDate |
2017 |
| language |
English |
| container_title |
Проблемы прочности |
| publisher |
Інститут проблем міцності ім. Г.С. Писаренко НАН України |
| format |
Article |
| title_alt |
Моделирование процесса поперечно-клиновой прокатки для изготовления ступенчатого вала методом конечных элементов |
| description |
The paper presents the results of numerical modeling of a cross-wedge rolling process for producing a stepped shaft. The modeling was performed with commercial software Forge NxT 1.1 using the finite element method. The numerical analysis enabled the determination of changes in the shape of the workpiece, effective strain, damage function and temperature distributions, as well as variations in the forces and torque acting on the tool. The numerical results demonstrate that personal computers can today be used to model even the most difficult cases of the cross-wedge rolling process, in which complex shapes of the tools and thermal phenomena occurring during the forming process have to be taken into consideration
Представлены результаты численного моделирования процесса поперечно-клиновой прокатки для изготовления ступенчатого вала. Моделирование выполнялось на базе коммерческой программы Forge NxT 1.1 с использованием метода конечных элементов. Численное решение позволило определить изменения формы изделия, эффективной деформации, функции повреждаемости и распределения температур, а также сил и крутящих моментов, действующих на вал. Показано, что для моделирования даже наиболее трудных случаев процесса ПКП, когда необходимо учитывать сложные конфигурации изделий и тепловые явления, возникающие в процессе формоизменения, могут использоваться персональные компьютеры.
|
| issn |
0556-171X |
| url |
https://nasplib.isofts.kiev.ua/handle/123456789/173687 |
| citation_txt |
FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft / Z. Pater, J. Tomczak, T. Bulzak // Проблемы прочности. — 2017. — № 4. — С. 43-53. — Бібліогр.: 81 назв. — англ. |
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| fulltext |
UDC 539.4
FEM Simulation of the Cross-Wedge Rolling Process for a Stepped Shaft
Z. Pater,
1
J. Tomczak,
2
and T. Bulzak
3
Lublin University of Technology, Lublin, Poland
1 z.pater@pollub.pl
2 j.tomczak@pollub.pl
3 t.bulzak@pollub.pl
The paper presents the results of numerical modeling of a cross-wedge rolling process for producing
a stepped shaft. The modeling was performed with commercial software Forge NxT 1.1 using the
finite element method. The numerical analysis enabled the determination of changes in the shape of
the workpiece, effective strain, damage function and temperature distributions, as well as variations
in the forces and torque acting on the tool. The numerical results demonstrate that personal
computers can today be used to model even the most difficult cases of the cross-wedge rolling
process, in which complex shapes of the tools and thermal phenomena occurring during the forming
process have to be taken into consideration.
Keywords: cross-wedge rolling, stepped shaft, tools design, numerical simulation, finite
element method.
Introduction. Cross-wedge rolling (CWR) belongs to the class of modern
metalworking processes, which have recently been gaining in popularity. This method is
mainly used in the production of stepped axles and shafts as well as preforms for drop
forging [1, 2].
CWR has several advantages, including high efficiency, good material utilization,
good strength properties of the products formed, environmental friendliness, low energy
consumption and easy automation [1, 2]. Despite these merits, CWR is not used as broadly
as it could in the manufacture of machine parts. This is mainly due to difficulties in
designing tools that would guarantee the accuracy of the rolling process. Even a slight
change in wedge angles may lead to problems such as uncontrolled slip, necking (fracture)
of the rolled product, or material cracking. Therefore, the design work related to launching
new CWR-based technologies is usually only done by designer teams employed by roller
machine producers. Even in this case, however, the final design (for products of more
complex shapes) is obtained via successive approximations, using the trial and error
method. As a result, the design and production of tools that can guarantee the expected
quality of rolled products is a time-consuming and costly process, which obviously has an
impact on the number of new implementations. This situation is expected to improve with
the widespread use of numerical techniques which allow modeling of complex metalworking
processes under three-dimensional strain. Numerical models make it possible to validate the
accuracy of a design in the virtual space of the computer, by simulating the forming
process. If the results are unsatisfactory, appropriate changes can be introduced to tool
design and the simulations can be repeated until an acceptable result is obtained.
CWR is one of the hardest metalworking processes to model numerically. This is
caused by the complex shape of the products, very large tool pitch (many times larger than
the dimensions of the workpiece), a complex interaction between the tool and the material
being formed (both slip and clinging of material can occur), and nonlinearities. Due to all
these facts, the CWR process was first successfully modeled using the finite element
method (FEM) as late as the end of the last century. Specialized literature offers
numerous examples of simulations of the CWR process performed using the following
© Z. PATER, J. TOMCZAK, T. BULZAK, 2017
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4 43
commercial programs: ANSYS/LS-DYNA [3–24], DEFORM-3D [25–65], Forge3 [66–69],
MSC.SuperForm, MARC.AutoForge, and Simufact.Forming [70–81]. Most of these
analyses have focused on the stability of rolling and determining the impact of the main
parameters of the process on the possibility of occurrence of defects. FEM has also been
used to analyze temperature distributions, microstructures, and stress-strain states of rolled
products. However, these analyses have been limited to simple cases of rolling, in which
often only a single reduction in the cross section of the product was being formed.
Currently, it is possible to model even very complex cases of CWR using a PC. This
means that this interesting metal forming method can be developed using virtual prototyping.
The aim of this paper is to demonstrate this claim using the example of numerical analysis
of CWR of a stepped shaft. It must be emphasized that the process of forming a stepped
shaft, which has been selected for numerical simulation, fully reflects the potential of
cross-wedge rolling, which, we believe, should have a much broader use than it has today.
Model of the CWR Process for a Stepped Shaft. Numerical simulations of the
CWR process were performed using the stepped shaft shown in Fig. 1, which had a more
complex shape than the shafts investigated in previous studies [3–81]. It was assumed that
the shaft would be formed by two wedge rollers (nominal diameter 800 mm) from a
� �72 110 mm billet, whose diameter was equal to that of the head of the forging. In this
situation, the shaft journals were to be formed at deformation ratios � (a measure of plastic
strain in CWR, where �� d d0 , d0 is the diameter of the billet and d is the diameter of
the step being rolled) reaching 3.33. Such a large reduction in diameter cannot be achieved
in one working cycle (a single pass of the wedges), and so forming must be done in two
operations (first the billet is rolled to an intermediate diameter and then to the target
diameter).
Figure 2 shows an unfolded view of the wedge tool (diameter 800 mm) used in the
cross wedge rolling of the stepped shaft. This figure also shows the overall dimensions of
the tool and the wedge spreading angles � (wedge geometry is described by two angles:
spreading angle � and forming angle �, defining the inclination of the wedge’s side wall;
in the case studied �� 22.5�). To obtain the desired shape of the shaft, it was necessary to
use a rolling scenario in which the excess stock (end faces with funnels formed in them)
was cut off from the product.
The analysis of CWR of the stepped shaft was carried out using the Forge NxT 1.1
commercial software package. Figure 3 shows a FEM model of the investigated CWR
Z. Pater, J. Tomczak, and T. Bulzak
44 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4
Fig. 1. Stepped shaft used in the numerical analysis.
process developed for computational purposes. The model consists of two wedge segments
(with a shape described using triangular surface elements), two guiding bars (guides) (for
holding the workpiece in the working space of the rollers), and a cylindrical billet
� �72 110 mm. Geometric models of the tools were imported from the Solid Edge CAD
system, in which they had been designed.
The product being formed was modeled using 4-node tetrahedral elements. Because
of the intense deformation of the metal, leading to considerable distortion of the final-
element grid, the grid rearrangement option was used in the calculations. It was enabled
when the increase in the strain in an element was larger 0.5. As a result, both the number of
nodes (in the range 9500–42,500) and the number of elements (42,500–165,000) used in
the calculations were changed (Fig. 4). The entire rolling process was divided into 4200
computational steps, and the computation time on a 32-core computer was 61 hours.
FEM Simulation of the Cross-Wedge Rolling Process ...
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4 45
Fig. 2. An unfolded view of the wedge segment used for the rolling of the stepped shaft shown in
Fig. 1 with marked wedge spreading angles �; wedge diameter 800 mm.
Fig. 3. Geometrical model of rolling a stepped shaft generated using Forge NxT 1.1 software.
It was assumed that the shaft was made of 19MnCr5 grade steel, a model of which
was obtained from the Forge NxT 1.1 library. The remaining parameters used in the
calculations were as follows: friction coefficient on the material–tool contact surface m� 1
for wedges and m� 0.2 for guides, roller rotational speed 10 rpm, billet temperature
1170�C, tool temperature 250�C, heat transfer coefficient between material and tools 10
kW/(m K2 ), and heat transfer coefficient between material and surroundings 200 W/(m K2 ).
Selected Calculation Results. FEM allows precise tracking of changes in product
shape during the rolling of the analyzed stepped shaft. The changes are shown in Fig. 5. In
the initial phase of the process, the wedge tools sink into the middle of the billet to reduce
its diameter. Once the two middle steps of the shaft have been formed, the smaller diameter
step downs located further to the shaft end, with diameters of 32.3 and 35 mm are rolled.
Then the head is formed. The tools used for rolling this portion of the forging were the
most difficult to design, because it was necessary to define the moment when the wedge
cuts into the material (this moment determines what volume of material will fill the space
between the wedges), which required correcting the design and repeating the calculations
several times. In further parts of the process, the smallest-diameter steps are formed with
the simultaneous loosening of the already formed middle steps. Next, the shaft is subjected
to final sizing in order to remove any shape errors that may have arisen in the previous
phases of the rolling process. At the end of the forming process, the unprocessed stock is
cut off from the ends of the product. Throughout the rolling process, the forging rotates
securely and there is no danger of uncontrolled slipping.
Figure 6 shows how the temperature is distributed in the rolled stepped shaft. Despite
the relatively long forming time (t
5.2 s) during which the shaft was in contact with the
tools, which have a much lower temperature (T � �250 C), no drop in material temperature
below the lower limit for metal forming was observed. The temperature of the metal was
the lowest in the middle steps of the shaft, which are formed in the initial phase of the
process and then, being rolled over the surfaces of the rollers, transfer the heat to the latter.
By contrast, the temperature in the inner layers of the shaft did not decrease significantly;
on the contrary, an increase was observed in some places. It is assumed that in these
portions of the product, the heat transferred to the tools during the heat exchange is
compensated by the heat generated by deformation and friction work.
46 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4
Z. Pater, J. Tomczak, and T. Bulzak
Fig. 4. Changes in the number of elements and nodes used in numerical calculations as a function of
rolling time.
Figure 7 shows the distribution of effective strain in the rolled stepped shaft. The data
in this figure indicate that strain increases with the reduction in diameter, with the strain in
the surface layers being higher than in the axial zone. This is the effect of the friction forces
acting on the material–tool contact surface. At the same time, it should be noted that the
strain in the shaft is very high, which cannot be the result of the reduction in diameter
alone. This fact can be explained by the intense flow of metal in the tangential direction
(mainly due to friction forces), which is characteristic of CWR and leads to the formation
of redundant strain in the metal.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4 47
FEM Simulation of the Cross-Wedge Rolling Process ...
Fig. 5. A Forge NxT 1.1 simulation of the course of the rolling process for a stepped shaft, with
colour-coded temperature distribution (in �C).
One of the common defects of CWR-formed products is internal cracking in the axial
zone (the Mannesmann effect). The crack formation can be predicted on the basis of an
analysis of the fracture (damage) function, calculated from the Cockroft–Latham ductile
fracture criterion. The fracture function for the investigated rolling process is shown in
Fig. 8. The data in this figure demonstrate that the extreme steps of the shaft, in which there
is a significant twisting of the material, are the most vulnerable to fracture. At the same
time, no increase in the fracture function in the axial zone of the formed shaft was
observed, indicating that the Mannesmann effect should not occur in the investigated shaft.
48 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4
Z. Pater, J. Tomczak, and T. Bulzak
Fig. 6 Fig. 7
Fig. 6. Temperature distribution in the stepped shaft (in �C) determined using Forge NxT 1.1.
Fig. 7. Effective strain distribution determined using Forge NxT 1.1.
Fig. 8. Distribution of damage function, according to the Cockroft–Latham criterion, determined
using Forge NxT 1.1.
Fig. 9 Fig. 10
Fig. 9. Distribution of radial load during forming of the analyzed stepped shaft.
Fig. 10. Distribution of torque acting on the roller during forming of the analyzed stepped shaft.
The distributions of two selected strength parameters of the rolling process, i.e., radial
force (perpendicular to the tool surface) and torque (which pushes the roller in the rolling
direction) are shown in Figs. 9 and 10, respectively. An analysis of the data given in these
figures demonstrates that both torque and radial force have the highest values in the initial
forming phase of the CWR process. It is at this stage that the contact surface between the
material and the tools is the largest. The smallest values of force parameters (several times
smaller than in the forming stages) are observed in the sizing phase.
Conclusions. This paper describes a thermo-mechanical model of cross-wedge rolling
of a stepped shaft. This model was used to perform a numerical simulation of rolling of the
analyzed shaft with the commercial software package Forge NxT 1.1. The calculations
were done to determine the successive changes in the shape of the shaft, temperature and
strain distributions, and the fracture criterion for the shaft. Also, distributions of radial force
and torque acting on the shaft during the rolling process were calculated. It was found that
a PC equipped with commercial software, such as Forge NxT 1.1, is sufficient to
successfully model such complex metal forming processes as cross-wedge rolling. This
means that design work related to launching new manufacturing processes based on the
modern CWR technology can be made easier by the application of numerical modeling.
This is especially important for individuals who are new to the CWR technology.
Acknowledgments. This scientific work was funded from the research and education
(statutory activity) fund granted by the Polish Ministry of Science and Higher Education to
the Faculty of Mechanical Engineering of the Lublin University of Technology.
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Received 01. 09. 2017
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FEM Simulation of the Cross-Wedge Rolling Process ...
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/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken die zijn geoptimaliseerd voor prepress-afdrukken van hoge kwaliteit. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)
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/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
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>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
/ErrorControl /WarnAndContinue
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/IncludeGuidesGrids false
/IncludeNonPrinting false
/IncludeSlug false
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(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
/AddColorBars false
/AddCropMarks false
/AddPageInfo false
/AddRegMarks false
/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
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/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
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/MultimediaHandling /UseObjectSettings
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/PDFXOutputIntentProfileSelector /DocumentCMYK
/PreserveEditing true
/UntaggedCMYKHandling /LeaveUntagged
/UntaggedRGBHandling /UseDocumentProfile
/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice
|