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Using upper bound solution to analyze force parameters of three-roll cross rolling of rings with small hole and deep groove

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Abstract

Three-roll cross rolling (TRCR) is a new advanced plastic forming technology to manufacture rings with small hole and deep groove (RSD), such as duplicate gear. Force parameters are the important basis for plastic forming technology design and equipment selection. So, it is necessary to establish a rational method of calculating force parameters. As the deformation process of TRCR is controlled by multifactors coupling interactive effects, to establish a universal design approach for comprehensive consideration of various parameters which affect the force and energy parameters, considering various kinds of factors with finite element analysis (FEA) method, a great quantity model and data analysis must be developed, which is more time-consuming and difficult to summarize the effective rule. While based on related supposition and simplified calculation, a common analytical method can be adopted quickly with the traditional plastic mechanics theory. Therefore, analytical models of rolling power, torque, and force are built in the paper, by means of the classic plastic mechanics theory of upper bound method combined with static analysis and calculation of kinematical admissible velocity field. Then, comparing to the results in FEA models of different sizes of workpieces and kinematic parameters of rolls under ABAQUS/Explicit environment, analytical models are corrected. As a consequence, the effect rules of workpiece sizes and roll kinematic parameters on force parameters display the same, and corrected analytical model has a great agreement with FEA, which provides reliable calculation basis for the design of force parameters in TRCR of RSD.

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Authors and Affiliations

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

    Lin Hua & Jiadong Deng

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

    Dongsheng Qian & Qi Ma

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

    Lin Hua, Jiadong Deng, Dongsheng Qian & Qi Ma

Authors
  1. Lin Hua
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  2. Jiadong Deng
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  3. Dongsheng Qian
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  4. Qi Ma
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Correspondence to Lin Hua or Dongsheng Qian.

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Hua, L., Deng, J., Qian, D. et al. Using upper bound solution to analyze force parameters of three-roll cross rolling of rings with small hole and deep groove. Int J Adv Manuf Technol 76, 353–366 (2015). https://doi.org/10.1007/s00170-014-6107-x

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  • DOI: https://doi.org/10.1007/s00170-014-6107-x

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