Research on forming technology of rotary forging with double symmetry rolls of large diameter : thickness ratio discs

<p>Rotary forging with double symmetry rolls (DSRs) is a new metal plastic forming technology developed on the basis of conventional rotary forging with a single roll, which uses a pair of symmetrical cone rolls to realize continuous local pressure plastic deformation of the workpiece. Large-d...

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Main Authors: R. F. Ma, C. D. Zhu, Y. F. Gao, Z. H. Wei
Format: Article
Language:English
Published: Copernicus Publications 2021-06-01
Series:Mechanical Sciences
Online Access:https://ms.copernicus.org/articles/12/625/2021/ms-12-625-2021.pdf
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spelling doaj-ede14498cdca4c04b32d8630326a0b6e2021-06-10T06:20:03ZengCopernicus PublicationsMechanical Sciences2191-91512191-916X2021-06-011262563810.5194/ms-12-625-2021Research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discsR. F. MaC. D. ZhuY. F. GaoZ. H. Wei<p>Rotary forging with double symmetry rolls (DSRs) is a new metal plastic forming technology developed on the basis of conventional rotary forging with a single roll, which uses a pair of symmetrical cone rolls to realize continuous local pressure plastic deformation of the workpiece. Large-diameter, thin discs are a key component in nuclear power, aerospace, deep-sea exploration, and other fields. At present, the forming process of large-diameter discs mainly includes welding and multiple local upsetting, but these processes exhibit many defects and can not meet the requirements of industry. In this paper, a large diameter : thickness ratio disc is integrally formed by rotary forging with DSRs. Using theoretical calculation and finite element simulation methods, the stable rolling conditions and calculation formulas of force and power parameters of rotary forging with DSRs of a large diameter : thickness ratio disc are derived. Based on the reliable three-dimensional rigid-plastic finite element model, the plastic deformation characteristics of rotary forging with DSRs of discs are studied, the reliability of the stable rolling conditions and the calculation formulas of force and power parameters are verified, and the defects and causes of unstable rolling conditions are analysed. An experiment was carried out on a rotary forging press developed with double symmetry rolls, and the experimental results are in good agreement with simulation results, which demonstrated that rotary forging with DSRs is a reliable technology for forming large diameter : thickness ratio discs. The results of this research are helpful to promote the further development of rotary forging with DSRs.</p>https://ms.copernicus.org/articles/12/625/2021/ms-12-625-2021.pdf
collection DOAJ
language English
format Article
sources DOAJ
author R. F. Ma
C. D. Zhu
Y. F. Gao
Z. H. Wei
spellingShingle R. F. Ma
C. D. Zhu
Y. F. Gao
Z. H. Wei
Research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discs
Mechanical Sciences
author_facet R. F. Ma
C. D. Zhu
Y. F. Gao
Z. H. Wei
author_sort R. F. Ma
title Research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discs
title_short Research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discs
title_full Research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discs
title_fullStr Research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discs
title_full_unstemmed Research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discs
title_sort research on forming technology of rotary forging with double symmetry rolls of large diameter&thinsp;:&thinsp;thickness ratio discs
publisher Copernicus Publications
series Mechanical Sciences
issn 2191-9151
2191-916X
publishDate 2021-06-01
description <p>Rotary forging with double symmetry rolls (DSRs) is a new metal plastic forming technology developed on the basis of conventional rotary forging with a single roll, which uses a pair of symmetrical cone rolls to realize continuous local pressure plastic deformation of the workpiece. Large-diameter, thin discs are a key component in nuclear power, aerospace, deep-sea exploration, and other fields. At present, the forming process of large-diameter discs mainly includes welding and multiple local upsetting, but these processes exhibit many defects and can not meet the requirements of industry. In this paper, a large diameter : thickness ratio disc is integrally formed by rotary forging with DSRs. Using theoretical calculation and finite element simulation methods, the stable rolling conditions and calculation formulas of force and power parameters of rotary forging with DSRs of a large diameter : thickness ratio disc are derived. Based on the reliable three-dimensional rigid-plastic finite element model, the plastic deformation characteristics of rotary forging with DSRs of discs are studied, the reliability of the stable rolling conditions and the calculation formulas of force and power parameters are verified, and the defects and causes of unstable rolling conditions are analysed. An experiment was carried out on a rotary forging press developed with double symmetry rolls, and the experimental results are in good agreement with simulation results, which demonstrated that rotary forging with DSRs is a reliable technology for forming large diameter : thickness ratio discs. The results of this research are helpful to promote the further development of rotary forging with DSRs.</p>
url https://ms.copernicus.org/articles/12/625/2021/ms-12-625-2021.pdf
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