Skip to main content
SpringerLink
Log in

3D thermomechanically coupled FEM analysis of large disk rolling process and trial production

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Recently, rolling technique used to manufacture rings with various dimensions, shapes, and materials is innovated to a revolutionary technique for the fabrication of large disks. In this paper, in order to study the forming capability of this novel method, its principle was introduced, and the 3D thermomechanically coupled FE model was established using the dynamic explicit code ABAQUS/Explicit. Considering the adaptive treatment of boundary conditions, the user subroutines of ABAQUS were explored based on the movement law of the guide rolls and profiled axial rolls, and contacts between these rolls and the disk component. And the reliability of the FE model was verified theoretically and experimentally. Furthermore, the extending rule of plastic deformation zone and the effect of feed speed on the size of both the outer and inner diameters were investigated. The main results show that (1) the smallest equivalent plastic strain (PEEQ) occurs at the hub of the disk and the junction of the rim and the web, and the larger PEEQ appears on the outer surface of the rim and the web of disk. (2) Both the outer and inner diameters of the disk increase gradually at the beginning stage and more and more rapidly at a later stage. With the increase of the feed rate, the increase rate of both the outer diameter and inner diameter will decrease and the lateral spread rate will increase. And trial production of the large disk based on the analysis had been carried out successfully on the revamped Wagner RAW500/400 radial-axial ring rolling mill.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Li QH, Wu LB, Li FG, Liu TY, Wang SG, Wei ZJ, Su CM (2013) Experiments study on the rolling process for heavy disk. Int J Adv Manuf Technol 65:1171–1175

    Article  Google Scholar 

  2. Bewlay BP, Gigliotti MFX, Hardwicke CU, Kaibyshev OA, Utyashev FZ, Salischev GA (2003) Net-shape manufacturing of aircraft engine disks by roll forming and hot die forging. J Mater Process Technol 135:324–329

    Article  Google Scholar 

  3. Li LY, Yang H, Guo LG, Sun ZC (2008) A control method of guide rolls in 3D-FE simulation of ring rolling. J Mater Process Technol 205:99–110

    Article  Google Scholar 

  4. Guo LG, Yang H (2011) Towards a steady forming condition for radial–axial ring rolling. Int J Mech Sci 53:286–299

    Article  Google Scholar 

  5. Wang ZW, Zeng SQ, Yang XH, Cheng C (2007) The key technology and realization of virtual ring rolling. J Mater Process Technol 182:374–381

    Article  Google Scholar 

  6. Wang ZW, Fan JP, Hu DP, Tang CY, Tsui CP (2010) Complete modeling and parameter optimization for virtual ring rolling. Int J Mech Sci 52:1325–1333

    Article  Google Scholar 

  7. Zhou G, Hua L, Qian DS (2011) 3D coupled thermo-mechanical FE analysis of roll size effects on the radial–axial ring rolling process. Comput Mater Sci 50:911–924

    Article  Google Scholar 

  8. Hua L, Qian DS, Pan LB (2009) Deformation behaviors and conditions in l-section profile cold ring rolling. J Mater Process Technol 209:5087–5096

    Article  Google Scholar 

  9. Yang H, Wang M, Guo LG, Sun ZC (2008) 3D coupled thermo-mechanical FE modeling of blank size effects on the uniformity of strain and temperature distributions during hot rolling of titanium alloy large rings. Comput Mater Sci 44:611–621

    Article  Google Scholar 

  10. Wang M, Yang H, Sun ZC, Guo LG, Ou XZ (2006) Dynamic explicit FE modeling of hot ring rolling process. Trans Nonferrous Metals Soc China 16:1274–1280

    Article  Google Scholar 

  11. Wang M, Yang H, Sun ZC, Guo LG (2009) Analysis of coupled mechanical and thermal behaviors in hot rolling of large rings of titanium alloy using 3D dynamic explicit FEM. J Mater Process Technol 209:3384–3395

    Article  Google Scholar 

  12. China aviation material manual. 2002. China Standard Press, Beijing, China

  13. Wang SG, Li QH, Li FG, Wei ZJ, Su CM (2011) Constitutive equations to high temperature flow stress of 0Cr11Ni2MoVNb stainless steel [J]. China Metal Forming Equipment & Manufacturing Technology 46:91–96

    Google Scholar 

  14. Song JL, Dowson AL, Jacobs MH, Brooks J, Beden I (2002) Coupled thermo-mechanical finite-element modelling of hot ring rolling process. J Mater Process Technol 121:332–340

    Article  Google Scholar 

  15. Davey K, Ward MJ (2003) An ALE approach for finite element ring-rolling simulation of profiled rings. J Mater Process Technol 139:559–566

    Article  Google Scholar 

  16. Forouzan MR, Salimi M, Gadala MS, Aljawi AA (2003) Guide roll simulation in FE analysis of ring rolling. J Mater Process Technol 142:213–223

    Article  Google Scholar 

  17. Yang H, Guo LG, Zhan M, Sun ZC (2006) Research on the influence of material properties on cold ring rolling processes by 3D-FE numerical simulation. J Mater Process Technol 177:634–638

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Qinghua Li, Zhanchao Ma & Fuguo Li

  2. Beijing Xinghang Mechanical & Equipment Plant, Beijing, 100074, China

    Taiying Liu

  3. Anda Aviation Forging CO., LTD, Anshun, 561000, China

    Zhijian Wei & Chunmin Su

Authors
  1. Qinghua Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhanchao Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Taiying Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Fuguo Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhijian Wei
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Chunmin Su
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Qinghua Li.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, Q., Ma, Z., Liu, T. et al. 3D thermomechanically coupled FEM analysis of large disk rolling process and trial production. Int J Adv Manuf Technol 74, 403–411 (2014). https://doi.org/10.1007/s00170-014-5985-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-5985-2

Keywords

Search

Navigation