Abstract
The article presents the results of model tests with which a comparative analysis of two methods of ball separation during the skew rolling process was carried out. A verification of the results obtained in the physical modelling process with the results obtained in the real process of skew ball rolling was also carried out. During the physical modelling, the effect of changing the ball separation method on the quality of the products obtained, variations in maximum torque values and maximum radial forces were analyzed. In the case of real tests, the results were verified with the results of physical modelling, in which the surface quality and torque values for one of the tool sets were compared. Physical modelling was used to verify the differences between the two methods of ball separation. Commercial plasticine based on synthetic wax from the manufacturer PRIMO was used as a model material for physical analysis. The plasticine used for testing was cooled to 0 °C and the cooling process took 24 h. The tools used for the physical modelling were 3D printed and the material used was ABS. The method of physical modelling using plasticine as a model material allows for a correct analysis of hot metal forming processes.
Highlights
A modelling material of the commercial plasticine type, which was produced by the manufacturer PRIMO (Italy, Via Bassa)—who manufacture products based on synthetic waxes—was used for physical modeling tests of the hot skew ball rolling process
The physical modelling studies carried out allowed comparison of the process of the skew rolling of balls with a diameter of 28.5 mm with two different sets of tools
It can be concluded that physical modelling allows for an accurate method of testing the skewed ball rolling process
Summary
The skew rolling of balls first physically modelled by Chitkar’s team [54], who in their publication presented an analysis of the effect of changing tool angle on the shape and quality of the final product For their study, they used white and black plasticine formed at room temperature. As a result of the analysis of laboratory studies of oblique ball rolling processes with screw rollers carried out so far, it has been observed that authors have not focused on the problem of modelling the ball separation process during rolling and it has been observed that the methods of ball separation significantly affect the quality of products obtained and the lifetime of tools It was considered appropriate in our research to undertake the subject of comparative analysis of two different methods of ball separation using physical modelling with verification in a real process on one of the tested sets of tools
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