New type of groove used to improve friction in roll forging

Abstract

A FEM model for a failed industrial example of roll forging was established to analyze the generation mechanisms of the mismatch of size and shape of two spring board. To demonstrate the formulation of these defects, the bites condition and contact status between rectangular groove and workpiece during rolling the first and second spring boards were analyzed. Then, a new oval-diamond groove combining oval groove and diamond groove was presented to eliminate these defects. By analyzing field variables under the same deformation degree, the larger friction can be obtained on the contact surface of workpiece and the oval-diamond groove. The physical experiment validates that the oval-diamond groove can eliminate these defects effectively, and the size of part is in good agreement with design requirement.

Keywords

roll forging / spring board / oval-diamond groove / rectangular groove / automobile front axles

References

[1] HuZ-h, ZhangK-s, WangB-y, ShuX-d, YangC-pingFormed technology and simulation of parts about the cross wedge rolling [M], 2004, Beijing, Metallurgical Industry Press: 1-3

[2] MinutoloF C, DuranteA, LanbiaseF, LangellaA. Dimensional analysis of a new type of groove for steel rebar rolling [J]. Journal of Materials Processing Technology, 2006, 175(1/2/3): 69-76

[3] KnapinskiM. The numerical analysis of roll deflection during plate rolling [J]. Journal of Materials Processing Technology, 2006, 175(1/2/3): 257-265

[4] BenasciuttiD, BrusaE, BazzaroG. Finite elements prediction of thermal stresses in work roll of hot rolling mills [J]. Procedia Engineering, 2010, 2(1): 707-716

[5] YooU K, LeeJ B, ParkJ H, LeeY. Analytical model for predicting the surface profile of a work piece in round-to-2-R and square-to-2-R oval groove rolling [J]. Journal of Mechanical Science and Technology, 2010, 24(11): 2289-2295

[6] KimW, KawaiK, KoyamaH, MiyazakiD. Fatigue strength and residual stress of groove-rolled products [J]. Journal of Materials Processing Technology, 2007, 194(1/2/3): 46-51

[7] ByonS M, NaD H, LeeY. Effect of roll gap adjustment on exit cross sectional shape in groove rolling-experimental and FE analysis [J]. Journal of Materials Processing Technology, 2009, 209(9): 4465-4470

[8] TianY, GuoY-h, WangZ-d, WangG-dong. Analysis of rolling pressure in asymmetrical rolling process by slab method [J]. Journal of Iron and Steel Research, International, 2009, 16(4): 22-26

[9] NaD H, ChoS H, LeeY. Experimental and numerical studies for the forming groove and separating groove design in slit rolling process [J]. Journal of Mechanical Science and Technology, 2011, 25(9): 2439-2446

[10] ShahaniA R, SetayeshiS, NodamaieS A, AsadiM A, RezareS. Prediction of influence parameters on the hot rolling process using finite element method and neural network [J]. Journal of Materials Processing Technology, 2009, 209(4): 1920-1935

[11] PellizzariM, CescatoD, De FloraM G. Hot friction and wear behavior of high speed and high chromium iron for rolls [J]. Wear, 2009, 267: 467-475

[12] SedighiM, MahmoodiM. An approach to simulate cold roll-forging of turbo-engine thin compressor blade [J]. Aircraft Engineering and Aerospace Technology, 2009, 81(3): 191-198

[13] LiR-x, JiaoS-h, WangJ-lv. Roll-forging technology of automotive front axle precision performing and die design [J]. IERI Procedia, 2012, 1: 166-171

[14] ErvastiE, StahlbergU. A quasi-3D method used for increasing the material yield in closed-die forging of a front axle beam [J]. Journal of Materials Processing Technology, 2005, 160(2): 119-122

[15] CaiZ-yi. Precision design of roll-forging die and its application in the forming of automobile front axles [J]. Journal of Materials Processing Technology, 2005, 168(1): 95-101