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Forming characteristics and mechanism of double-roll rotary forging for large-diameter and thin-walled metal discs

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Abstract

Double-roll rotary forging is an emerging plastic forming technology based on rotary forging. Owing to the advantages of labor saving, small eccentric load, low noise and vibration, good uniformity, high surface quality, and material saving, it is very promising for fabrication of large-diameter thin-walled disc. To date, a few relevant researches on the double-roll rotary forging technology of large-diameter thin-walled metal discs have been reported, and the forming mechanisms and process of disc workpieces remain uninvestigated. Herein, a 3D rigid-plastic finite element model (FEM) is established to simulate the fabrication process of large-diameter thin-walled disc; four geometric features appear in the forming process: “mushroom” shape, “upper drum” shape, “drum shape” shape, and “lower drum” shape. Equivalent stress, equivalent strain, and temperature field of these four geometric shapes are analyzed, and the forming mechanism of these four geometric shapes is revealed. The reliability and accuracy of FEM are verified through experiments, and the four geometric shape features occur in the process are consistent with the simulation. The research results provide valuable guidelines for better understanding of double-roll rotary forging for the fabrication of large-diameter thin-walled discs.

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Availability of data and material

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

The National Natural Science Foundation of China (No. 51875427) provided the support to this research.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Zhongquan Yu, Chundong Zhu, Mingchao Chen & Site Luo

  2. Industrial Research Institute of Wuhan University of Technology, Suizhou, 441399, China

    Chundong Zhu

Authors
  1. Zhongquan Yu
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  2. Chundong Zhu
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  3. Mingchao Chen
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  4. Site Luo
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Contributions

Zhongquan Yu and Chundong Zhu proposed the idea and performed the theoretical work. Zhongquan Yu and Chundong Zhu completed the writing of the paper. Zhongquan Yu, Mingchao Chen, and Site Luo performed the experimental work.

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Correspondence to Chundong Zhu.

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Yu, Z., Zhu, C., Chen, M. et al. Forming characteristics and mechanism of double-roll rotary forging for large-diameter and thin-walled metal discs. Int J Adv Manuf Technol 119, 7543–7555 (2022). https://doi.org/10.1007/s00170-022-08765-5

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  • DOI: https://doi.org/10.1007/s00170-022-08765-5

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