Simulation of ring rolling with new wax-based model materials on a flexible experimental machine

Abstract

Nowadays, the practice of using model materials for the analogical simulation of most forming processes is well established: however, the practice is almost non-existent in ring rolling. Important new opportunities for ring rolling have arisen due to a remarkable development over the last five years: highly unsymmetrical thin-walled rings and weld-neck flanges are being required to an increasing extent in high-cost materials such as aluminium alloy, stainless- and maraging-steels, heat-resisting alloys, titanium-, magnesium-, nickel-alloys and such-like. The present investigation explores the applications of the analogical-simulation method in ring-rolling sequences. For these applications, a new flexible horizontal machine has been developed for the rolling of model-material rings, the outer diameters of which do not exceed 700 mm. Typical rolling examples are concerned with the prediction of rolling forces and torques, with the analysis of flow patterns, and with some operating rules for idler and edging rolls. In addition to the demonstration of good agreement between the simulated and the actual rolling parameters, it is shown that the simulation on a flexible low-cost machine is an up-to-date and quick method for developing competitive ring-rolling procedures.