Skip to main content
SpringerLink
Log in

Cross wedge rolling of a Ti6Al4V (ELI) alloy: the experimental studies and the finite element simulation of the deformation and failure

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

Abstract

The cross wedge rolling (CWR) deformation and fracture of a Ti6Al4Al (ELI) alloy were investigated experimentally and numerically using a coupled thermo-mechanical finite element model analysis. The experimentally determined flow stress and damage model parameters were verified by tension split Hopkinson pressure bar testing of notched samples. The simulation and experimental CWR forces showed well agreements except near the end of the stretching zone. The model analysis showed that the temperature distribution in the work piece was non-uniform during the CWR. When the initial temperature of the work piece was relatively low, the work piece temperature increased, a heating effect of the plastic deformation, while relatively high initial work piece temperatures resulted in cooling the work piece, caused by the work piece contact with the tools. The cracks were shown numerically to initiate in the midsections of the work piece during the guiding action and elongated in a direction normal to the maximum tensile stress triaxiality, resulting in cruciform-shaped crack formation, which was well agreed with the previously observed crack shape.

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. Pater Z (1995) Theoretical method for estimation of mean pressure on contact area between rolling tools and workpiece in cross wedge rolling processes. In: International Conference on the Advances in Materials Processing Technologies (AMPT 95), Dublin, Ireland, Aug 1995. Pergamon-Elsevier, Oxford, pp. 233–243

  2. Dong Y, Tagavi KA, Lovell MR (2000) Analysis of interfacial slip in cross-wedge rolling: a numerical and phenomenological investigation. J Mater Process Technol 97(1–3):44–53

    Article  Google Scholar 

  3. Pater Z (1998) A study of cross wedge rolling process. J Mater Process Technol 80–1:370–375

    Article  Google Scholar 

  4. Johnson W, Mamalis AG (1977) A survey of some physical defects arising in metal working processes. Paper presented at the Proc 17th International MTDR Conference, London, UK

  5. Dong YM, Tagavi KA, Lovell MR, Deng Z (2000) Analysis of stress in cross wedge rolling with application to failure. Int J Mech Sci 42(7):1233–1253

    Article  MATH  Google Scholar 

  6. Li Q, Lovell MR (2004) The establishment of a failure criterion in cross wedge rolling. Int J Adv Manuf Technol 24(3–4):180–189. doi:10.1007/s00170-003-1607-0

    Google Scholar 

  7. Li Q, Lovell M (2005) On the critical interfacial friction of a two-roll CWR process. J Mater Process Technol 160(2):245–256. doi:10.1016/j.jmatprotec.2004.06.022

    Article  Google Scholar 

  8. Li Q, Lovell MR, Slaughter W, Tagavi K (2002) Investigation of the morphology of internal defects in cross wedge rolling. In: 9th International Conference on Metal Forming (METAL FORMING 2002, Birmingham, England, 09–11 Sep 2002. Elsevier, Amsterdam, pp. 248–257

  9. Dong YM, Lovell M, Tagavi K (1998) Analysis of interfacial slip in cross-wedge rolling: an experimentally verified finite-element model. J Mater Process Technol 80–1:273–281

    Article  Google Scholar 

  10. Fang G, Lei LP, Zeng P (2002) Three-dimensional rigid-plastic finite element simulation for the two-roll cross-wedge rolling process. In: 10th International Manufacturing Conference in China (IMCC 2002), Xiamen, People’s Republic of China, 11–13 Oct 2002. Elsevier, Amsterdam, pp. 245–249

  11. Li XT, Wang MT, Du FS (2006) The coupling thermal-mechanical and microstructural model for the FEM simulation of cross wedge rolling. J Mater Process Technol 172(2):202–207. doi:10.1016/j.jmatprotec.2005.10.011

    Article  Google Scholar 

  12. Pater Z (2006) Finite element analysis of cross wedge rolling. J Mater Process Technol 173(2):201–208. doi:10.1016/j.jmatprotec.2005.11.027

    Article  Google Scholar 

  13. Qiang YF, Song PB (2006) Analysis on temperature distribution in cross wedge rolling process with finite element method. In: 3rd International Conference on Advanced Forming and Die Manufacturing Technology, Busan, SOUTH KOREA, 04–06 Sep 2006. Elsevier, Amsterdam, pp. 392–396. doi:10.1016/j.jmatprotec.2006.11.193

  14. Wang MT, Li XT, Du FS, Zheng YZ (2005) A coupled thermal-mechanical and microstructural simulation of the cross wedge rolling process and experimental verification. Mater Sci Eng A-Struct Mater Prop Microstruct Process 391(1–2):305–312

    Article  Google Scholar 

  15. Urankar S, Lovell M, Morrow C, Li Q, Kawada K (2006) Establishment of failure conditions for the cross-wedge rolling of hollow shafts. In: 11th International Conference on Metal Forming 2006, Birmingham, ENGLAND, 11–13 Sep 2006. Elsevier, Amsterdam, pp. 545–549. doi:10.1016/j.jmatprotec.2006.04.052

  16. Lee HW, Lee GA, Yoon DJ, Choi S, Na KH, Hwang MY (2007) Optimization of design parameters using a response surface method in a cold cross-wedge rolling. In: 10th International Conference on Advances in Materials and Processing Technologies (AMPT2007), Daejeon, SOUTH KOREA, 07–11 Oct 2007. Elsevier, Amsterdam, pp. 112–117. doi:10.1016/j.jmatprotec.2007.11.287

  17. Wang MT, Li XT, Du FS, Zheng YZ (2004) Hot deformation of austenite and prediction of microstructure evolution of cross-wedge rolling. Mater Sci Eng A-Struct Mater Prop Microstruct Process 379(1–2):133–140. doi:10.1016/j.msea.2004.01.055

    Article  Google Scholar 

  18. Xiong Y, Sun SH, Li Y, Zhao J, Lv ZQ, Zhao DL, Zheng YZ, Fu WT (2006) Effect of warm cross-wedge rolling on microstructure and mechanical property of high carbon steel rods. Mater Sci Eng A-Struct Mater Prop Microstruct Process 431(1–2):152–157. doi:10.1016/j.msea.2006.05.148

    Article  Google Scholar 

  19. Johnson GR, Cook WH (1985) Fracture chracteristics of 3 metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21(1):31–48

    Article  Google Scholar 

  20. Bridgman PW (1952) Studies in large plastic flow and fracture. McGraw-Hill, New York

    MATH  Google Scholar 

  21. ASTM (2003) Standard specification for wrought titanium-6 aluminum-4 vanadium ELI (extra low interstitial) alloy for surgical implant applications. ASTM International, West Conshohocken. doi:10.1520/C0033-03, www.astm.org

  22. Chen W, Lu F, Cheng M (2002) Tension and compression tests of two polymers under quasi-static and dynamic loading. Polym Test 21(2):113–121

    Article  Google Scholar 

  23. Gray GT (2000) Classic split-Hopkinson pressure bar testing. In: Mechanical testing and evaluation, metals handbook, vol 8. American Society for Metals, Materials Park, pp. 462–476

  24. Meyers MA (1994) Dynamic behavior of materials. Wiley, New York

    Book  MATH  Google Scholar 

  25. Khan AS, Sung Suh Y, Kazmi R (2004) Quasi-static and dynamic loading responses and constitutive modeling of titanium alloys. Int J Plast 20(12):2233–2248

    Article  MATH  Google Scholar 

  26. Kıranlı E (2009) Determination of material constitutive equation of biomedical grade Ti6Al4V alloy for cross edge rolling. Izmir Institute of Technology, Izmir

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Dynamic Testing and Modeling Laboratory and Department of Mechanical Engineering, Izmir Institute of Technology, Gulbahce Koyu, Urla, Izmir, Turkey

    Metin Çakırcalı, Cenk Kılıçaslan, Mustafa Güden & Engin Kıranlı

  2. Physical Technical Institute of NAS Belarus, Minsk, Belarus

    Valery Y. Shchukin & Vladimir V. Petronko

Authors
  1. Metin Çakırcalı
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Cenk Kılıçaslan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mustafa Güden
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Engin Kıranlı
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Valery Y. Shchukin
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Vladimir V. Petronko
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mustafa Güden.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Çakırcalı, M., Kılıçaslan, C., Güden, M. et al. Cross wedge rolling of a Ti6Al4V (ELI) alloy: the experimental studies and the finite element simulation of the deformation and failure. Int J Adv Manuf Technol 65, 1273–1287 (2013). https://doi.org/10.1007/s00170-012-4256-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-012-4256-3

Keywords

Search

Navigation