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Design method for intermediate roll in multi-stage profile ring rolling process: The case for excavator idler rim

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Abstract

In this paper, the design method for intermediate rolls has been developed to manufacture excavator idler rims in multi-stage profile ring rolling process, based on the uniform volume distribution element technique (UVDET) and the extremum rolling ratio(λmax). UVDET is presented as the ratio of the volume change of ring blanks to that of undeformed rings per unit height. λmax is defined as the ratio of the cross-sectional area of blanks to that of rolled rings. The theoretical value of intermediate roll shapes were determined by UVDET and λmax, i.e. the outer diameter and cross-sectional shape of the intermediate ring, respectively. FE simulations and profile ring rolling experiments using AISI 1035 steel alloys were performed to prove the validity of proposed design method. In order to investigate the deformation behavior in profile ring rolling of excavator idler rims, the expanding rule of plastic zone should be carried out firstly. The proposed roll design method led to the successful ring shape and the highest dimensional precision.

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Authors and Affiliations

  1. PNU-IFAM Joint Research Center, Pusan National University, San 30, Jangjeon-dong, Geumjeong-gu, Busan, South Korea, 609-735

    Kyung-Hun Lee

  2. ERC/ITAF, Pusan National University, San 30, Jangjeon-dong, Geumjeong-gu, Busan, South Korea, 609-735

    Dae-Cheol Ko

  3. Department of Mechanical and Automotive Engineering, International University of Korea, 965, Dongburo Munsaneup, Jinju, Gyengnam, South Korea, 660-759

    Dong-Hwan Kim

  4. Faculty of Mechanical and Automotive Engineering, Keimyung University, 1000, Sindang-dong, Dalseo-gu, Daegu, South Korea, 704-701

    Seon-Bong Lee

  5. Production Department, KALTEK, 1064-1, Toerae-ri, Hanlim-myun, Kimhae, Gyeongnam, South Korea, 621-873

    Nag-Mun Sung

  6. School of Mechanical Engineering, Pusan National University, 30, Jangjeon-dong, Geumjeong-gu, Busan, South Korea, 609-735

    Byung-Min Kim

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  1. Kyung-Hun Lee
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Correspondence to Byung-Min Kim.

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Lee, KH., Ko, DC., Kim, DH. et al. Design method for intermediate roll in multi-stage profile ring rolling process: The case for excavator idler rim. Int. J. Precis. Eng. Manuf. 15, 503–512 (2014). https://doi.org/10.1007/s12541-014-0364-3

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  • DOI: https://doi.org/10.1007/s12541-014-0364-3

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