Abstract
The paper presents a complete numerical model of a helical-wedge rolling process for producing balls. The model was designed in Finite Element Method (FEM)-based Forge NxT v.1.1 that enables the simulation of both forming and separating balls. A comparison of numerical results with experimental findings revealed a very high agreement in both qualitative and quantitative terms. The developed numerical model was used to investigate the effect of flange shape on the helical-wedge rolling process for producing balls with a diameter of 125 mm. Three types of flange tools were investigated, and the best results were obtained for a wedge-shaped flange.
Highlights
Steel balls are widely used in the engineering industry, and in the processing sector as grinding media in ball mills for grinding metal ores, coal, gravel, used-up molding sands and many other materials
The results obtained helical rolling. This process could not, be verified in the experimental manner, due to from lack the tests were used to validate the discussed numerical model of helical rolling of balls, which of a rolling mill that would allow for rolling balls with such a big diameter
This of 57 mm The investigated helical-wedge rolling process for producing 57 mm diameter balls was modelled model consists of a billet, two helical rolls
Summary
Steel balls are widely used in the engineering industry (e.g., for producing rolling bearings), and in the processing sector as grinding media in ball mills for grinding metal ores, coal, gravel, used-up molding sands and many other materials. Helical-wedge rolling is considered the most efficient method for producing balls. In this process, balls are formed by two rolls positioned askew relative to the axis of the billet (cylindrical rod). Due to a rapid development of computer hardware and software for analysis of metal forming processes, some attempts have been made to model helical-wedge rolling of balls. Forming, this model did not, offer the possibility to simulate the separation of balls connected into “chains” by means. Given the balls results state-of-the-art complete numerical model 3oftoaanalyze helical-wedge producing withofa adiameter of 7.4 mm.survey, aFilippova et al. Model from the ones used far is the possibility of prognosticating the separation of balls, occurring as aTests resultofofathe material cracking, which happens once the damage criterion the
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