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Experimental and numerical study of cold helical rolling of small-diameter steel balls

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Abstract

Cold helical rolling (CHR) is one of the most effective ways to produce small-diameter steel balls. In this study, one kind of work hardening model was established and implemented into Simufact 15.0 to investigate the work hardening phenomenon in the cold forming process. Firstly, based on the helical rolling theory, a set of finite element (FE) simulations was developed. The influence of CHR parameters, including the starting height of convex rib, forming area length, and rolling inclination angle, on the forming process was studied via simulation. Furtherly, the CHR process experiment and FE simulation were carried out; the results showed that the FE simulation was in good agreement with the experimental results and consistent with the predicted value of the theoretical calculation. Finally, the evolution of effective strain, effective stress, rolling force, work hardening, and microstructure during the cold helical rolling of Φ 5.2-mm steel balls was investigated via FE. As a result, the evolution trend of hardness was consistent with that of dislocation density, indicating that the model is credible. Besides, the microstructure of the steel ball at different positions further verified this point.

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Availability of data and materials

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

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Funding

This work was supported by the Beijing Laboratory of Modern Transportation Metal Materials and Processing Technology. This work was also supported by the Beijing Key Laboratory of Metal Forming Lightweight.

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Authors and Affiliations

  1. School of Mechanical Engineering, University of Science and Technology Beijing, Beijing, 100083, China

    Shengqiang Liu, Jinping Liu, Hao Xu, Zhipeng Wang, Jinxia Shen & Baoyu Wang

  2. Engineering Research Center of Part Rolling, Ministry of Education, Beijing, China

    Jinping Liu & Baoyu Wang

Authors
  1. Shengqiang Liu
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  2. Jinping Liu
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  3. Hao Xu
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  4. Zhipeng Wang
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  5. Jinxia Shen
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Contributions

Shengqiang Liu: software, investigation, validation, methodology, writing—original draft. Jinping Liu: project administration, supervision, funding acquisition. Hao xu: supervision, writing—reviewing and editing. Zhipeng Wang: methodology, writing—reviewing and editing. Jinxia Shen: writing—reviewing and editing. Baoyu Wang: administration, supervision, funding acquisition.

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Correspondence to Jinping Liu or Baoyu Wang.

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Liu, S., Liu, J., Xu, H. et al. Experimental and numerical study of cold helical rolling of small-diameter steel balls. Int J Adv Manuf Technol 119, 599–613 (2022). https://doi.org/10.1007/s00170-021-08076-1

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