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

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Abstract

In the complex stepped-section profile ring rolling process, due to the complicated ring geometrical features and metal flowing relationship, the section profile of ring is difficult to fill. In this work, a blank design method of near-net rolling for complex stepped-section profile ring is explored. Firstly, through FE simulation, it is found that the use of rectangular and profile ring blank rolling will cause filling defects and folding defects of ring. Drawing on the idea of simplifying complexity, the target ring is divided into two typical parts; combined with rolling stability and ease of blank making, the combined correction design of ring blank is studied. In order to verify the rationality of the design theory, the optimized ring blank rolling process is simulated, and it is found that the designed ring blank has good forming effect. The dimensional change law of the forming process is further analyzed, and it is found that the dimensional change of the dividing ring blank has similar rules. The metal flowing law in the forming process is analyzed, and it is found that the metal basically does not flow along the axial direction on the dividing surface, which conforms to the conditions for selecting the dividing surface in the design theory. Finally, the reliability of design method is verified by rolling experiment, and the relative size error of the rolled ring is no more than 0.6%. Compared with the existing rolling process, the material utilization rate is increased by more than 40%.

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Data availability

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

Code availability

Not applicable.

Abbreviations

r 1 , r 2 , r 3 :

Inner radius of inner steps for target rolled ring

R 1 , R 2 , R 3 :

Outer radius of outer steps for target rolled ring

B o1 , B o2 , B o3 , B o4 :

Height of outer steps for target rolled ring

B i1 , B i2 , B i3 :

Height of inner steps for target rolled ring

B :

Total height of target rolled ring

V :

Volume of target rolled ring

ΔH :

Amount of rolling deformation

Δ \({{\varvec{H}}}_{{\varvec{g}}}\) :

Gap between the outer step 4 of the ring and driven roll

V A , V B :

Volume of divided parts I and II

B A , B B :

Height of divided parts I and II

ω :

Rotation speed of driven roll

v :

Feeding speed of mandrel

µ :

Coefficient of friction between roll and ring blank

r 01 , r 02 :

Inner radius of inner steps for ring blank No.3

R 01 , R f03 :

Outer radius of outer steps for ring blank No.3

B 01 :

Height of ring blank I0

B 02 :

Height of ring blank II0

B o04 :

Height of big ring of ring blank II0

V A0 , V B0 :

Volume of ring blanks I0 and II0

R 02 , R 03 :

Outer radius of small ring and big ring for ring blank II0

V 1 , V 2 :

Volume of correcting region for ring blank No.3

r m :

Radius of mandrel

Δ s :

Gap between mandrel and inner diameter of ring blank I0

D d-max :

Maximum diameter of driven roll

D m-max :

Maximum diameter of mandrel

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Funding

This research work is supported by the National Key Research and Development Project (2022YFB3705500), Hubei Key Research and Development Project (2022EJD012), 111 Project (B17034) for the supports given to this research.

Author information

Authors and Affiliations

  1. School of Automotive Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Rongwen Wu, Zhongyuan Sun & Jiadong Deng

  2. AECC Guizhou Liyang Aviation Power Co., Ltd, Guiyang, 550000, China

    Rongwen Wu

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

    Dongsheng Qian & Jian Lan

  4. Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan, 430070, China

    Jiadong Deng, Dongsheng Qian & Jian Lan

  5. Hubei Engineering Research Center for Green & Precision Material Forming, Wuhan University of Technology, Wuhan, 430070, China

    Jiadong Deng

Authors
  1. Rongwen Wu
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  2. Zhongyuan Sun
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  3. Jiadong Deng
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  4. Dongsheng Qian
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  5. Jian Lan
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Contributions

Rongwen Wu writes the manuscript of the paper and proposes the design optimization method of ring blank. Zhongyuan Sun reviews the paper. Jiadong Deng, Dongsheng Qian and Jian Lan provide the guidance of experimental implementation and provide correction schemes for process mold design.

Corresponding author

Correspondence to Jiadong Deng.

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Wu, R., Sun, Z., Deng, J. et al. A blank design optimization method of near-net ring rolling for complex stepped-section profile ring. Int J Adv Manuf Technol 127, 2425–2445 (2023). https://doi.org/10.1007/s00170-023-11678-6

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  • DOI: https://doi.org/10.1007/s00170-023-11678-6

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