Abstract
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.
Highlights
The intensive development of global industry at the end of the 19th century led to increased demand for semi-finished products in the form of balls
The most popular ball production techniques include helical rolling (Figure 1), in which the workpiece in the form of a bar is formed between two identical rolls that have helical grooves on their surface
This study has demonstrated that both the stability of the investigated helical rolling (HR) process and the product accuracy significantly depend on the helical tool geometry
Summary
The intensive development of global industry at the end of the 19th century led to increased demand for semi-finished products in the form of balls. It can be claimed that in the metal industry This mainly results from the difficulty in, first, designing the shape of the tool rolling processes with helical tools for manufacturing balls have not yet been thoroughly working surfaces such that they produce balls with the required parameters, and, constructing investigated, and, the current state of knowledge about these processes is far from exhaustive.
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