Skip to main content
SpringerLink
Log in

Influence of cooling condition of tools on central deformation of workpiece and tool wear in cross wedge rolling

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

Abstract

In this paper, a thermal–mechanical coupled simulation model for two-roll cross wedge rolling (CWR) was developed to investigate the influence of cooling condition of tools on central deformation of workpiece and tool wear by using three-dimensional rigid-plastic finite element method. Based on the simulation results, the information about central deformation of workpiece and tool wear with and without tool cooling was compared and analyzed. The study results indicate that forging quality and tool life can be improved by means of cooling the tools with cooling water. Subsequently, an industrial example of CWR in blank forming for engine connecting rod was presented to verify the feasibility of study results. In this industrial application, higher forging quality and longer tool life were obtained, which benefits the decrease of production cost. This study provides insights into the mechanisms of central deformation of workpiece and tool wear under different cooling conditions of tools in CWR process as well.

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. Song YQ, Wang MH, Li ZG (2010) One-way successive plate cross wedge rolling machine. Sci China Tech Sci 53(1):164–167

    Article  Google Scholar 

  2. Li Q, Lovell MR (2004) The establishment of a failure criterion in cross wedge rolling. Adv Manuf Technol 24:180–189

    Google Scholar 

  3. Johnson GR, Mamalis AG (1997) A survey of some physical defects arising in metal forming processes. In: Proceedings of the 17th International MTDR Conference, London, U.K.

  4. Fang G, Lei LP, Zeng P (2002) Three-dimensional rigid-plastic finite element simulation for the two-roll cross-wedge rolling process. J Mater Process Tech 129:245–249

    Article  Google Scholar 

  5. 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 391:305–312

    Article  Google Scholar 

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

    Article  Google Scholar 

  7. Bartnicki J, Pater Z (2005) Numerical simulation of three-rolls cross-wedge rolling of hollowed shaft. J Mater Process Tech 164–165:1154–1159

    Article  Google Scholar 

  8. Pater Z (2000) Theoretical and experimental analysis of cross wedge rolling process. Int J Mach Tools Manuf 40:49–63

    Article  Google Scholar 

  9. Li Q, Lovell MR (2003) Predicting critical friction in a two-roll cross wedge rolling process. J Tribol 125:200–203

    Article  Google Scholar 

  10. Li Q, Lovell MR (2005) On the critical interfacial friction of a two-roll CWR process. J Mater Process Tech 160:245–256

    Article  Google Scholar 

  11. Li Q, Lovell MR, Slaughter W, Tagavi K (2002) Investigation of the morphology of internal defects in cross wedge rolling. J Mater Process Tech 125–126:248–257

    Article  Google Scholar 

  12. Wang MT, Li XT, Du FS, Zheng YZ (2005) Hot deformation of Austenite and prediction of microstructure evolution of cross-wedge rolling. Mater Sci Eng 379:133–140

    Google Scholar 

  13. Wang MT, Li XT, Du FS (2009) Analysis of metal forming in two-roll cross wedge rolling process using finite element method. J Iron Steel Res Int 16:38–43

    Article  Google Scholar 

  14. Kchaou M, Elleuch R, Desplanques Y, Boidin X, Degallaix G (2010) Failure mechanisms of H13 die on relation to the forging process—a case study of brass gas valves. Eng Fail Anal 17:403–415

    Article  Google Scholar 

  15. Archard JF (1953) Contacts and rubbing of flat surface. J Appl Phys 24:981–988

    Article  Google Scholar 

  16. Chevalier L, Cloupet S, Soize C (2005) Probabilistic model for random uncertainties in steady state rolling contact. Wear 258:1543–1554

    Article  Google Scholar 

  17. Kim DH, Lee Y, Kin BM (2002) Application of ANN for the dimensional accuracy of workpiece in hot rod rolling process. J Mater Process Tech 130–131:214–218

    Article  Google Scholar 

  18. Dirks B, Enblom R (2011) Prediction model for wheel propfile wear and rolling contact fatigue. Wear 217:210–217

    Article  Google Scholar 

  19. Enblom R, Berg M (2005) Simulation of railway wheel profile development due to wear-influence of disc braking and contact environment. Wear 258:1055–1063

    Article  Google Scholar 

  20. Jendel T (2002) Prediction of wheel profile wear-comparisons with field measurements. Wear 253:89–99

    Article  Google Scholar 

  21. Li ZL, Kalker JJ (1998) Simulation of severe wheel-rail wear. Comput Railways VI 2:393–402

    Google Scholar 

  22. Jensen MR, Damborg FE, Nielsen KB, Dancert J (1998) Applying the finite element method for determination of tool wear in conventional deep drawing. J Mater Process Tech 83:98–105

    Article  Google Scholar 

  23. Wang KS, Liu QK, Zhang DY (2009) Numerical simulation of the tribological behaviour of the serial coatings of D2 steel. Acta Physica Sinica 58:89–93

    MathSciNet  Google Scholar 

  24. Brucelle O, Bernhart G (1999) Methodology for service life increase of hot forging tools. J Mater Process Tech 87:237–246

    Article  Google Scholar 

  25. Jung I, Lubich V, Wieland HJ (2002) Tool failure – causes and prevention. In: 6th International tooling conference, Sweden

  26. Persson A, Hogmark S, Bergstrom J (2005) Thermal fatigue cracking of surface engineered hot work tool steels. Surf Coat Tech 191:216–227

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. College of Material Science and Engineering, Chongqing University, Chongqing, People’s Republic of China

    Menghan Wang, Dong Xiang, Chuan Xiao, Jie Zhou & Zhi Jia

Authors
  1. Menghan Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Dong Xiang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chuan Xiao
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jie Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhi Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Dong Xiang.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Wang, M., Xiang, D., Xiao, C. et al. Influence of cooling condition of tools on central deformation of workpiece and tool wear in cross wedge rolling. Int J Adv Manuf Technol 59, 473–482 (2012). https://doi.org/10.1007/s00170-011-3537-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-011-3537-6

Keywords

Search

Navigation