Abstract
A new method of rotary plate forging with spiral grooved tools was proposed for the width expansion of a plate. This process consists of two stages: (1) plate width expansion with a pair of spiral grooved tools and (2) surface finishing rolling with a pair of camel-crown rolls. We performed finite element analysis to investigate the effect of tool geometry on the width expansion ratio, strain distribution in the plate and forming load. Compared with conventional rolling with straight cylindrical rolls, the effect of width expansion was observed in the proposed process with the spiral grooved tools. Four process conditions were examined to confirm the efficacy of the method; the pitch of the convex parts of the spiral grooved tools, process number and back tension in the traveling direction were changed in the analysis. From the results, it was found that the width expansion ratio was larger than that of the conventional rolling process. The back tension decreased the forming load and the magnitude of induced strain was generally larger than that of conventional rolling.
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