Abstract
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.
Highlights
Railway axles are manufactured from large-size forged parts that are produced in batches of several thousand pieces [1,2,3]
Skew rolling in a CNC rolling mill is highly effective and universal, and the forming forces and mills;rolling in a CNC rolling mill is highly effective and universal, and the forming forces and skew torques in this process are relatively low;
Skew-rolled hollow axles must be re-calibrated in order to form end steps; torques in this process aremust relatively low;
Summary
Railway axles are manufactured from large-size forged parts that are produced in batches of several thousand pieces [1,2,3]. To increase the manufacturing efficiency and decrease energy consumption of the production process for railway axles, studies were undertaken to investigate the possibility of manufacturing these parts by rolling methods. For this reason, studies were undertaken to investigate the possibility of forming these parts by multi-wedge rolling in which the workpiece is rolled by several pairs of wedges at the same time. [16],shown it was shown thatrolling skew requires rolling requires relatively low loads and a great advantage of this process is the possibility of producing parts ofparts different shapes torques. ForFor thisthis reason, an an analysis waswas carried outout to investigate the the possibility of using above rolling process for producing railway axles.
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