Abstract
Cross wedge rolling has the advantages of high production efficiency, good product quality, high material utilization, environmental protection, and low cost. It is one of the best processing methods for producing shaft blanks. In this paper, a cross wedge rolling die of TC4 titanium alloy is studied. Based on the Archard wear model, a modified model suitable for cross wedge rolling die wear analysis is derived through finite element simulation. Then, the modified Archard wear model is imported into Deform-3D software for finite element analysis. Orthogonal experimental design is used to combine and analyze different process parameters. Finally, the beetle antennae search (BAS)-genetic algorithm (GA)-back propagation neural network (BPNN) algorithm is used to predict the degree of die wear and to optimize the simulation parameters, which can acquire the process parameters that have the least impact on die wear. The results show that the wear distributions of cross wedge rolling tools is uneven. In general, the most serious areas are basically concentrated in the wedge-shaped inclined plane and rectangular edge lines. The reason is that the tangential force and radial force received by the die are relatively large, which leads to increased wear. Moreover, the temperature change is most severe on the wedge-shaped ridge line. When in contact with the workpiece, the temperature rises sharply, which makes the local temperature rise, the mold hardness decrease, and the wear accelerate. Through response surface method (RSM) analysis, it is concluded that the deformation temperature is the main factor affecting wear depth, followed by the forming angle, and that there is an interaction between the two factors. Finally, the feasibility of the BAS-GA-BP algorithm for optimizing the wear behavior of dies is verified, which provides a new process parameter optimization method for the problem of die wear in the cross wedge rolling process.
Highlights
Compared with other traditional machining processes, cross wedge rolling has the advantages of high production efficiency, good product quality, environmental protection, and low cost [4]
Ti-6Al-4V alloy and JIS SKD 61 (AISI H13) die steel are used for workpiece and cross wedge rolling die, respectively
The die-wear characteristics during CWR of Ti-6Al-4V titanium revealed by the finite element method
Summary
In the process of cross wedge rolling, the failure mode of the die is more complicated. The task of reducing die wear has become an important issue in cross wedge rolling production. Detection and search functions are realized by imitating the search function and random walking mechanism of the beetle in nature, which shows wide applicability and effectiveness in solving the multi-objective function-optimization problem It is simple and flexible, avoids local optimal solutions, and is suitable for high-dimensional search. It is economically costly to study the relationship between mold-wear depth and cross wedge rolling process parameters through experimental methods. Finite element simulation analysis of the cross wedge rolling process with different combinations of process parameters is carried out through Deform3D software, and the influences of different parameters on die wear is analyzed. The research results can provide theoretical guidance and technical support for die-wear behaviors
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