Ring Rolling Research Articles

Study on Cavity Filling Defects and Tensile Properties of L-Shaped Profiled Rings

Severe cavity filling defects and poor mechanical properties increase the difficulty in the integrated forming of L-shaped profiled rings due to its asymmetrical section geometry. A novel rolling method of a C-shaped ring was proposed in this study, and two symmetric L-shaped rings were prepared simultaneously. A numerical model of C-shaped ring rolling was established, and the cavity filling defects in different directions and the overall forming defect were defined for a qualitative analysis of the geometry’s accuracy. The effect of the rolling parameters on the forming defects and ring quality was investigated. The forming defects increased with an increase in the groove depth ratio as well as decreases in the groove angle and rolling ratio. The feeding strategy with a constant ring growth velocity led to the best geometric accuracy and strain uniformity of the C-shaped rings. Optimized rolling parameters can be acquired by the Box–Behnken optimization method with multi-objective optimization of the rolling stability and ring quality. An experiment of C-shaped ring rolling was successfully prepared, based on the optimized parameters. The hardness distribution on the cross-section was symmetric and uniform. The C-shaped ring showed obvious anisotropy of the tensile properties of the cast ring’s blank, and heat treatment had little effect on the improvement of the isotropy.

Ring rolling with flat dies: An analytical method to optimize geometry, time or energy

Ring rolling with flat dies: An analytical method to optimize geometry, time or energy

Evaluation Methods and Coupled Optimization at Macro- and Micro-Scales for Profiled Ring Rolling of Inconel718 Alloy.

The forming quality of profiled ring rolling not only encompasses macroscopic accuracy but also emphasizes the microstructure. Due to the multiple process parameters and complex metal flow during profiled ring rolling, the various forming defects are difficult to control and difficult to study theoretically. The objective of this study is to establish a comprehensive method for evaluating the forming quality of profiled rings, which considers both the macroscopic forming accuracy and the microstructure. Firstly, the synthetic size factor was defined, and the evolutionary relation between the section forming rate and the diameter growth rate of E-section ring rolling was analyzed in detail. The synthetic size factor can be used to describe the dimensional evolution and evaluate the forming accuracy of the profiled ring rolling process. Taking into full consideration the features of intermittent deformation in local areas, a microstructure evolution model of the Inconel718 alloy during E-section ring rolling, which can accurately predict the recrystallization volume fraction and average grain size of the final ring, was established. Then, combined with finite element simulation, the influence of the rotation speed of the driving roll on the macro-size evolution and microstructure was systematically analyzed. The results indicate that there is often a discrepancy between dimensional accuracy and microstructure uniformity in the optimization trend. For instance, the higher the rotation speed of the driving roll is, the more uniform the microstructure is, but the more difficult it is for the section profile to form. Finally, combined with response surface methodology (RSM), multi-parameter optimization was carried out with section forming accuracy and grain uniformity as the optimization objectives. By using the optimal parameters, an E-section ring with a complete profile and a uniform microstructure was obtained, with a maximum prediction error of the recrystallization volume fraction lower than 5%. The results show that the macroscopic and microscopic quality evaluation methods proposed in this study, as well as the optimization method combining RSM, can be effectively applied to the process optimization of profiled ring rolling.

Extension of a Contact Subroutine for Composite Ring Rolling to Include Temperature Dependency

By combining the ring rolling and roll bonding processes, the product spectrum can be additionally expanded. Since a successful composite ring rolling process requires a higher growth tendency for the inner ring, previous publications commonly included a softer inner ring to reduce the flow resistance of the inner ring or specific geometries for rings and tools. In this work, the material combination of a 100Cr6 (DIN 1.3505, AISI 52100) outer ring and a 42CrMo4 (DIN 1.7225, AISI 4140) inner ring is used to show that the composite ring rolling process is also possible for material combinations with a balanced flow stress ratio and equal wall thicknesses. In earlier publications, the influence of temperature was neglected. As the influence on the yield stress and thus on the success of the process has a significant influence, this should be considered in order to be able to make a reliable statement. For this purpose, the bond formation of the two materials was investigated by bonding experiments, and an existing bond formation model was extended with respect to the temperature dependency. On the basis of this model, the process control parameters were investigated using FE simulations, and a ring rolling experiment was carried out.

An inclusive comparative study on the influences of the ring rolling process at elevated temperatures on the mechanical properties and microstructures of two centrifugally cast light alloys

An inclusive comparative study on the influences of the ring rolling process at elevated temperatures on the mechanical properties and microstructures of two centrifugally cast light alloys

Numerical Simulation as a Tool for the Study, Development, and Optimization of Rolling Processes: A Review

Rolling is one of the most important processes in the metallurgical industry due to its versatility. Despite its inherent advantages, design and manufacturing by rolling still rely on trial-and-error-based optimizations, which reduces its efficiency. To minimize the cost and time spent on the development of new rolling schedules, various analytical and numerical methods have been used in recent years. Among other alternatives, simulations based on the finite element method (FEM) are the most widely used. This allows for the analysis of the feasibility of new rolling schedules considering metal alloys with different characteristics, process conditions, or the creation of new operations, as well as the optimization of existing ones. This paper presents a literature review including the latest developments in the field of numerical simulation of rolling processes, which have been classified according to the type of rolling into the following categories: flat rolling, shape rolling, ring rolling, cross-wedge rolling, skew rolling, and tube piercing.

Evolution and formation mechanism of residual stress in Al-Cu alloy rings during ring rolling and quenching

The large-scale ring components, as thin-walled structures, are prone to unpredictable machining deformation due to the initial residual stresses introduced by rolling and quenching, which seriously affect the dimensional accuracy and service life of the ring components. Therefore, the relief and homogenization of residual stress inside large-scale ring components is crucial. However, the existing studies rarely involve the essential causes and the evolution laws of residual stresses during the manufacturing of ring components, which are indispensable for understanding the failure mechanisms of components caused by residual stresses and specifying relevant protective measures. Therefore, the evolution and distribution laws of stress-microstructure-property non-uniformity during the hot forming (ring rolling) and heat treatment (quenching) of 2219 Al-Cu alloy rings were precisely and deeply explored using scaled experiments in this paper. The relationship between non-uniform deformation and residual stresses was analyzed, and the basic equation that residual stresses must satisfy was established. Furthermore, the concept of the “non-coordination coefficient” was proposed, revealing the physical mechanism of residual stresses induced by non-uniform deformation. In addition, the influencing factors and formation mechanisms of residual stresses in the rolled and quenched state of rings were studied, and the essential reasons for the differences in residual stresses between the rolling and quenching processes were obtained. The experimental results indicate that the circumferential and axial residual stresses increased from 1.48 and 0.51 MPa to −142.68 and −122.31 MPa, respectively. The standard deviation changed from 13.47 and 33.52 MPa to 63.42 and 61.61 MPa, respectively. The maximum range of tensile strength, yield strength and elongation rates of the rolling and quenched state is 12.82 and 20.16 MPa, 17.49 and 22.14 MPa, and 8.62 % and 7.56 %, respectively. All fractures are microporous aggregation ductile, including dimple transgranular fracture and intergranular fracture. The quenched state exhibits a significantly larger grain size compared to the rolled state. The appearance of residual stress is essentially to force the inconsistent deformation of various parts inside the object to maintain its integrity and continuity, which leads to a local mismatch of micro-elements inside the ring and further induces non-uniform strain and stress. The difference in the severity of “penetrability” induced by different temperature gradients determines the difference in residual stress between rolled and quenched rings, larger rings have higher and more non-uniform residual stress than smaller rings under the same process conditions. The above results deepen the theoretical understanding of residual stress formation mechanisms and lay a theoretical foundation for the comprehensive evaluation of performance degradation and service failure analysis of large ring components.

Gas-liquid flow regimes in a novel rocking and rolling flow loop

Predicting two-phase flow pattern characteristics and flow transition is fundamental to address several industrial problems, e.g. for the oil and gas industry. In order to fulfil the upscaling from the laboratory to the industrial scale, resource-efficient flow testing facilities which closely replicate industrial flow characteristics are needed. To address this, we introduce a new experimental device named as the Rocking and Rolling Ring Flow Loop (3RFL), which is size, cost, and time-efficient. In the present work, we employ the 3RFL apparatus at atmospheric pressure and temperature, with air and water as working fluids. However, the ultimate goal of our work is to build an experimental set-up capable of capturing the under-pressure reactive multiphase flow (gas-liquid–solid) dynamics typical of flow assurance in oil production and transportation. At the moment, the 3RFL can induce different flow regimes by adjusting the system control parameters such as rocking angle, rocking rate, and liquid volume fraction, all without requiring a pump. We observe three flow regimes, and analyse the impact of control parameters on their emergence. Our findings reveal that flow regime transitions are influenced by the competition between gravitational and centrifugal forces, which arise due to the curvature of the tube. Among three employed modelling strategies, namely mechanistic modelling, total energy minimization and a combined approach, we find that the total energy minimization model best compares to the experimental liquid height.

Optimizing profiled ring preforms for enhanced deformation uniformity using the isothermal field method

One of the main challenges faced by the profiled ring rolling (PRR) process is to ensure the deformation uniformity of the ring, which is closely related to the design of the ring preform. The paper explores the application of the isothermal field method (IFM) in designing preforms for PRR processes, targeting the aerospace sector's high-end equipment manufacturing. Through the integration of advanced computational models and practical design principles, a comprehensive approach involving IFM, finite element simulation, support vector machine modeling, and genetic algorithm optimization is employed to determine the geometric dimensions of rational preforms. The material flow behavior during the PRR process is analyzed, and the effects of different isotherms combinations on strain, stress and temperature distribution are discussed. The findings demonstrate that adjusting the preform's shape during the section forming stage can optimize the uniformity of strain, stress, and temperature within the forging. The stable ring rolling process revealed no macroscopic or microscopic defects, validating the design method of ring preform based on IFM is reasonable. The research contributes to advancing near-net shape forming technologies, offering a novel approach to preform design that marries theoretical analysis with practical manufacturability considerations.

On the Fundamentals of Reverse Ring Rolling: A Numerical Proof of Concept.

Ring Rolling is a near-net manufacturing process with some measurable dimensional inaccuracies in its products. This fact is exaggerated even more under the scope of high-precision manufacturing, where these imprecisions render such products unfitting for the strict dimensional requirements of high-precision applications (e.g., bearings, casings for turbojets, etc.). In order to remedy some of the dimensional inaccuracies of Ring Rolling, the novel approach of Reverse Ring Rolling is proposed and investigated in the current analysis. The conducted research was based on a numerical simulation of a flat Ring Rolling process, previously presented by the authors. Since the final dimensions of the ring from the authors' previous work diverged from those initially expected, the simulation of a subsequent Reverse Ring Rolling process was performed to reach the target dimensions. The calculated deformational results revealed a great agreement in at least two of the three crucial dimensions. Additionally, the evaluation of the calculated stress, strain, temperature and load results revealed key aspects of the mechanisms that occur during the proposed process. Overall, it was concluded that Reverse Ring Rolling can effectively function as a corrective process, which can increase the dimensional accuracy of a seamless ring product with little additional post-processing and cost.

Analysis of failure characteristics of screen plates of ring hammer crusher used in coal handling applications

The screen plate, a critical component within a ring hammer crusher (also known as a ring granulator or rolling ring crusher), plays a vital role in the secondary crushing of coal. Functioning both as a platform for coal crushing and as a sieve to achieve the desired coal size, it is essential to understand and examine its failure characteristics to enhance its mechanical and wear resistance properties in coal handling applications. This study thoroughly explored the failure modes, mechanisms, and underlying causes of screen plate failures. Microscopic techniques such as optical microscopy (OM), scanning electron microscopy (SEM), Vickers microhardness test and spectrochemical analysis were utilised to identify the failure mechanism. Failure modes identified from the macroscopic analysis were discharged hole widening, hole wall break-off, plate edge crack, plate fracture, one-sided edge slimming, and general surface wear of the screen plate. The fractographic and wear track analysis identified the principal failure mechanisms of three-body abrasive wear, two-body sliding abrasion wear, shear-induced fatigue fracture and brittle shear fracture. The root causes of the failures are the rotor’s direct impact, defects in the parent material, the presence of hard materials in the coal and the use of unsuitable steel grade in the screen plate manufacturing. The service life of the screen plate can be improved through proper material selection, uniform crusher feeding, surface modification of the surface of the “as purchase” screen plate with appropriate wear-resistant materials, and adherence to good maintenance practices.

Rolling Eccentric Steel Rings on an Industrial Radial–Axial Ring Rolling Mill

Various industries, including mechanical engineering, utilize steel rings featuring variable cross-sectional profiles, such as eccentric rings. Presently employed methods for producing eccentric rings possess drawbacks like restricted geometries, significant material wastage or uneven microstructures. The radial–axial ring rolling process serves to create seamless rolled steel rings with near-net-shaped cross-sections. A novel technique involves achieving eccentricity by dynamically adjusting the mandrel’s position during the ring rolling process. This method’s fundamental feasibility has previously been showcased using a blend of oil clay and a labor test bench. Transferring the possibility of manufacturing eccentric rings on industrial radial–axial ring rolling mills would expand the product range of ring manufacturers without encountering drawbacks associated with existing manufacturing processes. The objective of this paper is to demonstrate the basic feasibility of the concept of an industrial radial–axial ring rolling mill. In the first step, FEA simulation studies were carried out to develop the rolling strategy and estimate the achievable eccentricity on the institute’s radial–axial ring mill. Subsequently, the rolling strategy was implemented on an industrial ring rolling mill with the help of a unique technology module programmed in C++. Finally, an eccentric ring was ring rolled and compared with the FEA simulation, and the reproducibility was demonstrated to be successful.

Analysis of Kinematics and Dynamics of Rolling Ring Based on Finite Element Method

The working performance of the conductive rolling ring has a crucial impact on the overall energy security and on-orbit life of a satellite. To ensure the real-time transmission of signal and current, it is necessary to control the motion pattern of the rolling ring. In this paper, the finite element analysis method is used to carry out kinematics and dynamics simulation analysis, analyze the motion stability of the rolling ring, and discuss the relationship between the size of the idler gear, the driving torque, and the flexible contact pressure. The research results show that the numerical simulation and theoretical analysis show that the deviation angle is between 0 and 1.52 when the initial installation of the rolling ring is deviated by using the existing camber design of the inner and outer rings. Both have a self-recovery function. The driving torque and the size of the idler gear are nonlinear, and the contact force is proportional to the radius of the idler gear. With the increase in the compression of the radius of the flexible ring, the driving torque and the contact force will increase accordingly. The method of reducing the compression or increasing the size of the idler gear can be used to reduce the driving torque and maintain a certain contact to facilitate the transmission of electrical signals.

Buckling Defect Optimization of Constrained Ring Rolling of Thin-Walled Conical Rings with Inner High Ribs Combining Response Surface Method with FEM

A buckling defect will appear on the outer surface of the deformed ring during the constrained ring rolling (CRR) of an aluminum alloy thin-wall conical ring with inner high ribs (AATWCRIHR) if the geometrical dimension of the ribs does not match the wall thickness. To avoid the buckling defect, a quantitative method for characterizing the degree of the buckling defect is proposed using the area of the buckling profile. Then, an orthogonal experimental scheme was designed, taking the width of the middle rib, thickness of wall, and height of the middle rib as the design variables and defining the area of the buckling profile as the optimization objective. Subsequently, a quadratic polynomial response surface model was established by combining the optimization algorithm with the finite element method (FEM), and the geometrical dimension of the middle ribs of the deformed AATWCRIHR is optimized. Moreover, the optimal parameter combination to minimize the area of the buckling profile is obtained and verified using FE simulation. The results show that the AATWCRIHR after optimization does not generate the buckling defect during constrained ring rolling, and it is proven that the quantitative buckling defect representation method and the optimization design method based on the response surface model and the finite element simulation results are feasible for the constrained ring-rolling process of the AATWCRIHR.

Study of real-time parameter measurement of ring rolling pieces based on machine vision.

Real time parameter measurement cannot be carried out to dynamic ring parts during automation ring rolling processes so that rolling process parameters cannot be adjusted in time. Considering effects of shaping of ring rolling parts, a visual measurement platform was set up and a machine vision-based non-contact real -time measurement method was put forward. This article improves the subpixel level edge extraction algorithm to extract edge data information of circular rolling pieces. Based on the characteristics of circular rolling pieces, an RG-Hough transform method is proposed to fit the detected edge data information. The conversion relationship between pixel and actual sizes were determined in combination with the camera calibration to gain parameters of ring rolling parts. Measurements of ring parts (OD: 462.12mm; and ID: 315.53mm) were applied to verify the effectiveness of our method. Our measurement error is ±0.25mm and our average speed can be up to 104ms/frame. Our study can provide powerful technical supports for intelligent control of ring rolling pieces.

A rapid prediction method for geometric size in profiled ring rolling process

A rapid prediction method for geometric size in profiled ring rolling process

Hot Deformation Behavior of Inconel 718 Alloy Using Regression-based Dynamic Material Model and Applications in Ring Rolling Manufacturing

Inconel 718 nickel-based alloy is extensively used in the aerospace industry (e.g., gas turbine engine components) because of its excellent corrosion resistance and high mechanical properties at elevated temperatures. However, there is a certain limit to manufacturing the alloy through plastic deformation due to its high deformation resistance and complicated deformation behaviors. In this study, the hot deformation behavior of Inconel 718 alloy was investigated to establish how processing conditions of flow stress-strain, at strain rates from 0.001 to 10 s<sup>-1</sup>, and temperatures from 850 to 1200<sup>o</sup>C, affected dynamic recrystallization. The regression-based material model was utilized to calculate the strain-rate sensitivity, and subsequently depict the efficiency of the power dissipation and instability criterion of hot deformation. The processing map and instability criterion predicted by the developed 3<sup>rd</sup>-order polynomial regression model corresponded with the experimental results and in particular, showed a better prediction for instability regime compared to the existing discrete derivative approach. Predicting the strain-rate sensitivity values on a continuous scale with regression analysis covered the additional instability region of the high strain rate near 10 s<sup>-1</sup>. The dynamic recrystallization deformation was also characterized by microstructural analysis along with the processing map. Consequently, ring-rolled aviation parts were manufactured with the optimum processing parameters, which conform to the AMS 5663 standard (Aerospace material specifications for Inconel 718).

A multi-objective optimization workflow of ring-rolling process parameters based on production energy and time

Our industrial era is characterized by a significant attention to environmental aspects and production sustainability. Under this point of view, the minimization of the process energy represents a milestone leading to a consistent reduction of pollution. However, to promptly react to the high production rate market request, companies employ time saving manufacturing strategies, often in contrast with this principle. Considering this, an optimization concerning the reduction of both production time and energy, results to be strategical, especially when energy-intensive processes, such as ring rolling, are considered. Ring rolling is a shaping process performed by a dedicated equipment, composed of a driving roll, an idle roll, and a couple of axial rolls, allowing to obtain seamless rings while simultaneously reducing their height and thickness, while enlarging diameter. The kinematics of each component of the equipment can be set independently. This leads to several process conditions influencing quality, energy, and times, and makes it difficult the selection of the most suitable configuration. In this paper, a multi-objective optimization workflow is presented. Starting from validated FEM simulation campaign results, the proposed methodology allowed to individuate the best process parameters combination for limiting energy and time, encouraging its application to a wider range of energy-consuming processes.

Research the Dimensional Accuracy of C45 Steel Ring Forgings Produced by Radial Rolling.

The rolling process of rings is a commonly used method for producing annular forgings. There are two primary types of this process: radial-axial rolling and radial rolling. This article presents the research results regarding the latter, in which obtaining a product with the assumed dimensions constitutes a major problem. In industrial practice, the process parameters are based on the experience of technologists and/or by trial and error. This is why the authors considered it justified to undertake the research aimed at determining the influence of the main process parameters, that is, preform temperature and tool speed, on the shape and dimensions of the cross-section, which determine the internal and external diameters of the rolled ring. The research was based on numerical simulations and experimental studies. The results obtained proved that the higher the feed speed of the main roll, the greater the change in the cross-sectional height during rolling, and the smaller the cross-sectional deformation (the so-called fishtail). Nevertheless, a higher preform temperature reduces the final height of the ring and reduces cross-section deformation. On the basis of the obtained test results, guidelines for the process design were postulated, considering the influence of temperature and speed parameters on the final dimensions of the forging and the dimensions of the preform.

Forming process chain for manufacturing complex conical-section profiled rings: On a co-design method

The final quality of complex conical-section rings depends on co-design of multiple processes in forming process chain. In this study, for a complex aeroengine casing ring with a large slope and a flange on its end, a co-design method of the forming process chain is put forward towards the objective of precision forming, which not only proposes a standard process route composed of multiple processes of upsetting, punching, rectangular ring rolling, loose tooling forging and profiled ring rolling, but also presents co-design methods of dies and blanks for all the processes. For profiled ring rolling, a design method of preformed blank that makes the blank and the target conical-section ring have the same axial volume distribution is proposed. By the method, the axial metal redistribution during the process can be alleviated greatly thus improving the forming stability and precision of the ring. Based on the geometric features of designed preformed blank, design methods of blanks and dies for loose tolling forging, rectangular ring rolling, punching and upsetting are proposed sequentially. In view of the key roles of loose tooling forging (manufacturing the preformed blank) and profiled ring rolling on the final quality of the conical ring parts, inherited FE simulations for these two processes are performed to verify the proposed design methods and determine appropriate design parameter. It is demonstrated that the proposed design method has significant advantages in improving forming precision. Besides, a suggestive value 1.5 of the rolling ratio for profiled ring rolling (a key design parameter) is given based on comprehensive consideration of multiple indicators such as ring roundness, deformation uniformity and forming load. The corresponding industrial experiments performed illustrate that a high forming precision of the conical-section aeroengine casing ring is achieved.