Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls

This paper begins with a brief overview of the methods for producing balls. It then discusses the rolling processes for producing balls in helical passes. Next, a method for designing tools for helical rolling (HR) is described. Six different cases of rolling using tools with helical passes of diffe...

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Main Authors:	Andrzej Gontarz, Janusz Tomczak, Zbigniew Pater, Tomasz Bulzak
Format:	Article
Language:	English
Published:	MDPI AG 2019-09-01
Series:	Materials
Subjects:	steel balls helical rolling helix tools
Online Access:	https://www.mdpi.com/1996-1944/12/18/2917

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spelling	doaj-1aca6e92677a48bb9c643a15307708012020-11-25T01:09:43ZengMDPI AGMaterials1996-19442019-09-011218291710.3390/ma12182917ma12182917Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel BallsAndrzej Gontarz0Janusz Tomczak1Zbigniew Pater2Tomasz Bulzak3Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36, 20-618 Lublin, PolandFaculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36, 20-618 Lublin, PolandFaculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36, 20-618 Lublin, PolandFaculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36, 20-618 Lublin, PolandThis paper begins with a brief overview of the methods for producing balls. It then discusses the rolling processes for producing balls in helical passes. Next, a method for designing tools for helical rolling (HR) is described. Six different cases of rolling using tools with helical passes of different lengths are modeled by the finite element method (FEM). The simulations are performed with the use of Simufact Forming version 13.3. Based on the 3D simulations, the distributions of effective strain, damage criterion, and temperature, as well as the variations in loads and torques, are determined. This study also predicts the rate and manner of wear of the helical tools, depending on the tool design. As a result, it has been found that an increased length of the helical forming passes is advantageous in terms of tool service life. It has also been found that excessive elongation of the forming zone is not cost-effective.https://www.mdpi.com/1996-1944/12/18/2917steel ballshelical rollinghelix tools
collection	DOAJ
language	English
format	Article
sources	DOAJ
author	Andrzej Gontarz Janusz Tomczak Zbigniew Pater Tomasz Bulzak
spellingShingle	Andrzej Gontarz Janusz Tomczak Zbigniew Pater Tomasz Bulzak Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls Materials steel balls helical rolling helix tools
author_facet	Andrzej Gontarz Janusz Tomczak Zbigniew Pater Tomasz Bulzak
author_sort	Andrzej Gontarz
title	Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls
title_short	Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls
title_full	Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls
title_fullStr	Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls
title_full_unstemmed	Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls
title_sort	effect of the forming zone length on helical rolling processes for manufacturing steel balls
publisher	MDPI AG
series	Materials
issn	1996-1944
publishDate	2019-09-01
description	This paper begins with a brief overview of the methods for producing balls. It then discusses the rolling processes for producing balls in helical passes. Next, a method for designing tools for helical rolling (HR) is described. Six different cases of rolling using tools with helical passes of different lengths are modeled by the finite element method (FEM). The simulations are performed with the use of Simufact Forming version 13.3. Based on the 3D simulations, the distributions of effective strain, damage criterion, and temperature, as well as the variations in loads and torques, are determined. This study also predicts the rate and manner of wear of the helical tools, depending on the tool design. As a result, it has been found that an increased length of the helical forming passes is advantageous in terms of tool service life. It has also been found that excessive elongation of the forming zone is not cost-effective.
topic	steel balls helical rolling helix tools
url	https://www.mdpi.com/1996-1944/12/18/2917
work_keys_str_mv	AT andrzejgontarz effectoftheformingzonelengthonhelicalrollingprocessesformanufacturingsteelballs AT janusztomczak effectoftheformingzonelengthonhelicalrollingprocessesformanufacturingsteelballs AT zbigniewpater effectoftheformingzonelengthonhelicalrollingprocessesformanufacturingsteelballs AT tomaszbulzak effectoftheformingzonelengthonhelicalrollingprocessesformanufacturingsteelballs
_version_	1725177063452704768

Effect of the Forming Zone Length on Helical Rolling Processes for Manufacturing Steel Balls

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