Abstract
Double-roll rotary forging is an emerging plastic forming technology based on rotary forging. Owing to the advantages of being labor-saving, a small eccentric load, low noise and vibration, good uniformity, high surface quality, and material saving, it is very promising for the fabrication of large diameter thin-walled disks. To date, little relevant research on the double-roll rotary forging technology of large diameter thin-walled metal disks has been reported, and the deformation characteristic and the influence of three key parameters on the double-roll rotary forging process remain uninvestigated. Herein, a reasonable 3D rigid-plastic numerical model of the double-roll rotary forging of a disk workpiece is established under the Deform software environment. Based on the valid 3D numerical model, the deformation mechanism, and the effective laws of three key parameters (feed rate v of the lower die, rotational speed n of the upper die, and the initial temperature T of the disk workpiece) on the metal flow and force and power parameters in the double-roll rotary forging process have been explored. The research results provide valuable guidelines for a better understanding of double-roll rotary forging for the fabrication of large diameter thin-walled disks.
Highlights
Large diameter and thin-walled metal discs are key components in nuclear power, aerospace, deep-sea exploration, and other industrial fields
To study the influence of the feed rate v of the lower die on the metal flow and force and power parameters, we used calculation scheme 2 as follows: feed rate v of the lower die is specified as variable, and choosing v = 0.5, 1, 1.5, 2, 2.5 mm/s, the rotational speed of the upper die n = 75 rad/min, and the initial temperature of the disk workpiece T = 1100 ◦C, the value of parameters is selected by Equation (6)
To study the influence of the rotational speed n of the upper die on metal flow and force and power parameters, we used calculation scheme 3 as follows: rotational speed n of the upper die is specified as variable, and, by choosing n =50, 75, 100, 125, 150, 175 rad/min, feed rate of the lower die v = 1 mm/s, and the initial temperature of the disk workpiece T = 1100 ◦C, the value of parameters is selected by Equation (6)
Summary
Large diameter and thin-walled metal discs are key components in nuclear power, aerospace, deep-sea exploration, and other industrial fields. We [25] proposed for the first time a double-roll rotary forging method and designed the double-roll forging machine, which transformed the single roll into two symmetrical rolls along the central axis of the two main shafts This technology remarkably eliminated the influence of the eccentric load of the workpiece during the forming process, and broke through the forming size limit of the rotary forging process, making it possible to form a large diameter thin-wall disk workpiece. The working principle of double-roll rotary forging and the integral forming of large diameter thin-walled metal disk is shown in Figure 1: The double rollers continuously rotate around the central axis of the main shaft of the equipment, and the lower die simultaneously feeds the disk workpiece upwards. As soon as the disk workpiece is formed to the target height, the lower die stops feeding upwards, while the double rollers continue to rotate to flatten the upper surface of the disk workpiece
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