Ring Rolling Research Articles

A prediction model of ultimate forming dimension for profile ring with outer groove in ring rolling process

A prediction model of ultimate forming dimension for profile ring with outer groove in ring rolling process

Development of a measurement method for tracking the position of hot steel rings on an industrial radial-axial ring rolling mill

Development of a measurement method for tracking the position of hot steel rings on an industrial radial-axial ring rolling mill

A four-tensor momenta equation for rolling physics

Relativistic four-tensor equation dJ μ ν = M μ ν dt is developed to analyse linear translation with rotation processes. The postulated cause-effect four-tensor equation, a relativistic generalisation for classical angular-impulse–angular-momentum variation equation dJ = Mdt, includes the Poinsot-Euler rotation (angular-impulse–angular-momentum variation) equation, Newton’s second law (linear-impulse–linear-momentum variation equation), and thermodynamics first law (work–energy equation). This four-tensor formalism is applied to describe three linear translation with rotation processes: a ring rolling on the floor by a horizontal force linear impulse and torque, fulfilling the rolling condition (mechanical energy conservation), a spinning ring placed on the ground until achieved the rolling condition (mechanical energy dissipation by friction), and a fireworks wheel ascending an incline (mechanical energy production by decreasing a thermodynamic potential).

An innovative rotary rolling-forging process for manufacturing fork ring with extreme geometry

Fork ring is a key structural component of rocket fuel tank, which is difficult to be manufactured with high performance and high efficiency because of its extreme geometry and strict performance requirement. This paper proposes an innovative rotary rolling-forging (RRF) process to realize high performance and high efficiency manufacturing of fork ring. Firstly, the principle of RRF process of fork ring is proposed by combining the advantages of ring rolling and rotary forging. Secondly, the interference determination criterion of RRF die and fork ring is established and the effective die parameter windows are determined, and consequently the die design method for RRF of fork ring is proposed. Thirdly, the mechanical model for predicting the metal flow in RRF process of fork ring is developed by slab method and the uneven growth mechanisms of three ribs are revealed. It is found that the lower rib is the most difficult to be formed and its height hardly increases because of the large metal flow resistance. Based on the above results, the design method for preformed billet is proposed to realize the growth control of three ribs. Finally, the experiments of RRF of fork ring are conducted and it is verified that the proposed RRF process of fork ring and corresponding process design method are feasible.

Multi-scale simulation of flow behavior and microstructure evolution for AA2219 alloy during multi-pass ring rolling process

The multi-scale simulation of flow behavior and microstructure evolution of 2219 aluminum alloy during ring rolling was conducted. A new forming technology with two-stage hot−warm ring rolling was proposed compared to conventional hot rolling. The results show that the distributions of temperature, strain and strain rate are inhomogeneous on the cross section. The grains of edge nodes are elongated resulting from the larger strain and the low-angle grain boundaries transform into high-angle grain boundaries resulting in the increased fraction of recrystallization in hot rolling. The elongated banded structures change to equiaxed grains during the solution treatment, indicating complete static recrystallization. The inhomogeneous distributions of the temperature and strain result in heterogeneous microstructure distribution. The rolling force and the geometry of the ring were analyzed with experiment. The tensile properties in all directions of the ring and its isotropy are significantly increased with the new technology, especially the elongation.

Evaluation method of filling difficulty for profile ring rolling cavity based on FEM and RSM

During the rolling process of profile ring, the design of the rolling cavity directly affects the forming quality of the final ring. In order to improve the cavity filling rate and reduce the production cycle time, this paper proposes a general evaluation method of the filling difficulty for profile ring rolling cavity by combining the response surface method(RSM) and the finite element method(FEM) with the step-type ring as the research object. Firstly, a universally applicable design method for profile ring rolling cavity is proposed, and based on the description of the rolling cavity, three design variables and a corresponding response objective are defined to achieve multi-objective optimization. Secondly, a finite element model of this step-type ring rolling process is established, and the response model is built and improved by significance analysis and analysis of variance(ANOVA) based on the forming simulation results. Then, the effects of different variables on the optimization objectives are comprehensively investigated by this response model. Finally, the evaluation method of the filling difficulty for profile ring rolling cavity is obtained by combining the contour plot of the response objective.

Analytical calculation model for radial-axial coordinated feed strategy in large-scale flat ring rolling based on ultimate bending moment

Analytical calculation model for radial-axial coordinated feed strategy in large-scale flat ring rolling based on ultimate bending moment

The real-time vision measurement of multi geometric information of the rolled ring in the hot ring rolling process based on deep learning

Hot ring rolling (HRR) is an advanced incremental metal-forming technology to manufacture high-performance rings. Nowadays, the mechanical or laser-sensors measurement methods can only obtain one value of the dimensions on the ring circumference per time unit, the measurement data is single and the information is limited. This paper presents a real-time vision measurement method for multi geometric information of the rolled ring such as ring’s diameter, center position, circularity and growth speed in HRR process. Firstly, the deep learning model is constructed to intelligently and quickly identify rolled ring targets from complex image backgrounds, then the adaptive linear gray scale transformation algorithm is proposed to adjust the gray scale contrast of the image according to changes in ring temperature, the interference of oxide scales and flying chips are eliminated by morphology operation. Finally, the least square method is used to fit the contour points, and further the rolled ring’s geometric information and corresponding variation trend are calculated. Several experiments are conducted on a vertical HRR mill, the geometric information of the rolled ring during the HRR is measured in real-time under the interference of harsh working conditions. For the ring with outer diameter of 350 mm, the measurement error of ring’s outer and inner diameter is less than 0.8 mm, the average processing time per image takes about 80 ms. The research provides a basis for accurate measurement of HRR process.

Simulation of the forming of jet engine compressor spools by ring rolling process

simulation of the forming of jet engine compressor spools by ring rolling process

Response behavior of grain evolution to forming conditions during hot ring rolling of as-cast 100Cr6 steel

Response behavior of grain evolution to forming conditions during hot ring rolling of as-cast 100Cr6 steel

Motor rolling bearing fault diagnosis based on MVMD energy entropy and GWO-SVM

For motor rolling bearing fault diagnosis, vibration signal analysis is a common method to extract sensitive fault characteristics. In this paper, a newly signal processing method, multivariate variational mode decomposition (MVMD), is proposed to extract features from motor rolling bearings. The MVMD was carried out on the motor rolling bearings state signals of different categories, and the prior parameter K value which had a great influence on the decomposition effect was analyzed. Each component obtained by decomposition was measured in the form of energy entropy (EE), and the measured feature information was classified and identified by support vector machine (SVM) classifier. Meanwhile, the grey wolf optimization (GWO) was used to optimize the parameters of the classifier network to further improve the recognition accuracy. Through the simulation results, it is found that the scheme can achieve 100 % effect on the diagnosis rate of normal working condition, outer ring fault, inner ring fault and rolling element fault under the condition of different load and speed of the motor rolling bearing.

Effects of the Radial-Axial Ring Rolling Process on the Mechanical Properties and Microstructure of Centrifugally Cast AM60 Magnesium Rings

Effects of the Radial-Axial Ring Rolling Process on the Mechanical Properties and Microstructure of Centrifugally Cast AM60 Magnesium Rings

Large-scale assembly of geometrically diverse metal nanoparticles-based 3D plasmonic DNA nanostructures for SERS detection of PNK in cancer cells

The organization of geometrically diverse metal nanoparticles into a core/satellite structure at a large scale is a promising strategy for improve SERS performance due to hot spots localized enrichment and signal increase. However, due to the lack of extensional frames and strong electrostatic repulsion between plasma NPs, the fabrication of such 3D architectures with a high-density periodic hotspot in the focus volume has proven exceedingly difficult. Herein, we demonstrate a facile large-scale assembly of geometrically diverse metal nanoparticles strategy for constructing spatially extended 3D plasmonic nanostructures resembling “signal towers” based on RCA-mediated periodic organization of gold nanospheres (GNS) surrounding gold nanorods (GNRs). Using cancer cell T4 PNK as a model, a padlock probe with 5′- hydroxyl (P-circle) was designed as the T4 PNK substrate. The center Au nanorod was coated with P1 and served as a “pedestal” to allow substantial loading of P-circle after target phosphorylation to initiate the rolling ring amplification reaction (RCA). The resultant DNA nanowire serves as an “antenna” to successively lock numerous Raman reporter P2 (Cy3-P2-SH) through base pairing at regular intervals. Finally, the 3D plasma DNA nanostructures that resemble “signal towers” could be obtained by placing a large number of GNS with a strong affinity for Au–S. The proposed 3D SERS sensor exhibited a sensitivity of LOD as low as 0.274 mU/mL, which was attributed to a substantial electromagnetic field enhancement at the inter-nanoparticle gaps between the adjacent pedestal and antenna. Moreover, by exploiting the synergistic effect of the periodically extended DNA scaffold generated by RCA amplification and the co-assembly of thiol ligand, the loaded GNS can be extended to three-dimensional space, forming a high-density periodic hotspot in the focal volume, thereby ensuring high enhancement and high reproducibility of Raman signals. In addition, this method can be used to quantify T4 PNK in HeLa cells, demonstrating its applicability in diagnosing and estimating PNK-related diseases in complex fluids.

Residual stresses evolution and process route optimization of TC4 profiled rolled rings incorporating thermal bulging

Residual stresses evolution and process route optimization of TC4 profiled rolled rings incorporating thermal bulging

Development of microstructural heterogeneities and dynamic restoration activity during ring rolling of Ti-6Al-4V alloy and its tensile response

Ring rolling is one of the advanced metal forming processes to produce seamless rings. Being a bulk forming process, inhomogeneity in the distribution of strain and temperature can be anticipated in the ring cross-sections. This, in turn, is expected to influence the evolution of microstructure and correspondingly the mechanical properties. Processing of Ti‐6Al‐4V alloy is equally challenging because of its poor thermal conductivity and formability with a limited deformation window. Ti‐6Al‐4V preforms were rolled at elevated temperature under two different main roll feed rates to obtain approximately 30 % deformation in the lab scale ring rolling facility. The evolution of microstructure, including crystallographic texture, was examined as a function of feed rate at different locations of the rings using electron backscattered diffraction (EBSD) technique, and subsequently the tensile response of the rings at selected locations was evaluated at room temperature. The effect of feed rate was found to be marginal on the microstructure evolution; however, there were substantial differences in grain sizes and texture evolution in the regions from inner to outer side of the ring cross-section. Coarse grains were seen at centre region of the ring, while fine grains were present in the region near inner diameter of the ring. Surface regions which experienced more deformation developed basal texture, while the interior regions possessed shear texture after ring rolling. Detailed analysis of the EBSD results suggested orientation dependent continuous dynamic recrystallization as the restoration mechanism in the alloy during ring rolling. The effect of feed rate on the tensile response of the ring rolled alloy was found to be negligible; however, the tensile strength of the ring varied with the location, in accordance with the microstructural heterogeneity. This study provides proper basis for quality control and better understanding for technical guidance required for designing the ring rolling process, specifically for Ti‐6Al‐4V alloy.

Temperature control for thermomechanical ring rolling

Thermomechanical tangential profiled ring rolling enables the manufacture of ring shaped parts with specified geometry and hardness within a single step. Some influence over the cooling rate of the ring is achieved using supplementary cooling with compressed air. Earlier work has shown that some form of control is necessary in order to obtain an acceptable reproducibility. In this study, the possibility to control the temperature of the ring using closed loop control is shown. A model of the controlled system is implemented in order to determine PID parameters. Finally, the improvement of the process repeatability is demonstrated.

A blank design optimization method of near-net ring rolling for complex stepped-section profile ring

A blank design optimization method of near-net ring rolling for complex stepped-section profile ring

РАЗРАБОТКИ ПОДПРОГРАММЫ «МЕТАЛЛУРГИЯ», ВЫПОЛНЕННЫЕ В ИНТЕРЕСАХ ПРОМЫШЛЕННЫХ ПРЕДПРИЯТИЙ

The main results of the implementation of the tasks of the subprogram “Metallurgy” of the State Research Program “Mechanics, Metallurgy, Diagnostics in Mechanical Engineering”, 2021–2025, with an applied orientation are presented, which are obtained by the organizations of the National Academy of Sciences of Belarus, the Ministry of Education and the Ministry of Industry of the Republic of Belarus. Their contribution to the solution of practical problems is shown. In the field of metallurgy of iron-carbon alloys, a range of new grades of steels for large gears and large castings of supporting systems of machines are developed. Distinctive features of the developed steels are the possibility to obtain higher hardness values of the hardened layer and teeth of cemented gears compared with counterparts from serial steels. A new sparingly alloyed steel for gearboxes of tractors BELARUS has been developed. The steel is characterized by high hardenability of cemented layer. In the field of metallurgy of non-ferrous metals and alloys, theoretical and technological bases for production of complex configuration castings are developed. Application of these castings improves the dimensional accuracy of products. In the field of hardening of steels and alloys, the technology of coating formation on the working surfaces of metallurgical and foundry equipment parts by mechanical cladding with flexible tool is developed. The coatings provide 1.9 times higher durability of mold parts by compared to the parts without coatings. The technological process of induction cladding on the surfaces of friction nodes parts of wear-resistant antifriction coatings is developed. The service life of bimetallic parts with coatings is 1.25–1.33 times higher than that of serial parts. Physico-chemical principles of creation of aluminomatrix composites were developed on the basis of micro- and ultradispersed oxide powders. This provided a 5-fold increase in tribomechanical properties. In the field of metal forming, the strategy of ring rolling is developed as applied to the nomenclature of rings of the Belarusian enterprises. Technological substantiation is performed for reducing deformations and residual stresses after heat treatment of low-rigid parts such as discs using dynamic stabilization based on alternating cyclic loading.

Process Window and Repeatability of Thermomechanical Tangential Ring Rolling

International objectives towards improved resource and energy efficiency require new manufacturing processes, such as the proposed thermomechanical tangential profiled ring rolling process. A rapid cooling-down for microstructural adjustment and a final calibration step via cold forming are combined into one single step. The reduction of process steps and the reduced number of heating cycles present opportunities for improved energy efficiency compared to traditional processes. Based on a series of experiments, this paper aims at showing the potential of this new process in terms of obtainable hardness and microstructure. The influence of the active cooling system and the rolling feed is demonstrated. They are identified as essential with regard to both the geometry and the microstructural properties of the produced part. Finally, the repeatability of the process is analyzed, and potential disturbances are identified and ranked.

Single-Port Robotic Transvesical Simple Prostatectomy Step by Step

We detail the instruments required to perform a single-port robotic transvesical simple prostatectomy, as well as the surgical technique to perform this operation using the single-port robot. A 3-cm transverse incision is made three fingerbreadths above the pubic symphysis and a longitudinal cystotomy is made. The roll wound retractor rolling ring is inserted into the bladder lumen, with the access port, SP Short Entry Guide, and AirSeal trocar within it. The robot is then docked to the SP cannula, and the bladder is insufflated to 8 mm Hg. A semilunar incision is made through the bladder mucosa using the monopolar scissors along the posterior aspect of the bladder neck or median lobe. The forceps can be used to retract the prostatic adenoma, while using the monopolar scissors to further bluntly dissect the adenoma from the capsule. The prostatic adenoma can be removed en bloc, but is usually removed en lobe. A vesicourethral mucosal advancement flap is performed with 3-0 V-Loc suture from apex to base at 3-o-clock and 9-o-clock; a double-arm 3-0 V-Loc suture is then used to approximate the bladder and urethral mucosa, by running from 6-o-clock to 12-o-clock. Prostatic adenoma specimens can be removed from the SP Access Port directly or removed from the bladder using the robotic camera for observation. The cystotomy is closed in two layers with 3-0 Vicryl suture. The patient is observed for 2 hours on continuous bladder irrigation to determine ambulatory discharge eligibility. Follow-up is in 3 to 7 days for trial of void. Disclosure: Portions of this video and title were presented at the AUA 2023 in the form of a video abstract and as an AUA Core Curriculum video. https://www.auajournals.org/doi/pdf/10.1097/JU.0000000000003288.06 Patient Consent Statement: Authors have received and archived patient consent for video recording/publication in advance of video recording of procedure. There are no commercial associations during the past 3 years that might create a conflict of interest in connection with the video. Runtime of video: 7 mins 37 secs