Three-roll Planetary Rolling Mill Process Force

At present, the domestic and foreign metal rolling technology trend of development is:the large scale production by highly efficiency, the craft of short flow, the production line continued operation, the small environmental pollution and the low energy consumption. Three-roll planetary mill (PSW) is the most representative short flow essential equipment. The large deformation in a single pass and good capability of no-torsion continuous rolling are its merits. PSW can be used to roll steel, non-ferrous metals and hard deforming alloy material. In the formation of rod, wire-rod and tubing, it is used widely day by day. Speaking of the domestic and foreign theoretics study on PSW, although it has acquired certain research results, it still need to be studied in many respects. This paper separately uses traditional theory method and finite element method to research workpiece's deformation process and rolling force.The paper briefly narrates emergence, development, transmission principle, merits and faults of PSW. On the basis of summarizing predecessors'research results of designing PSW, contact area has analyzed in detail with the differential geometry model and geometrical relationship research between roller and workpiece. According to the differential principle which Kalman solves unit pressure, unit pressure of the deformed area is obtained. And then the integral equation of rolling force is gotten. Finally the rolling force and rolling torque are obtained by means of numerical analysis method. On the basis of the actual rolling condition, the paper selects suitable rolling parameters and uses the software of Visual Basic to program. We can get the rolling force, the rolling torque and the power of motor.According to the basic theory of finite element method, the solution process of big elastoplastic finite element method and explicit dynamics finite element method are deduced. The author uses triumphantly finite element analysis software ANSYS/LS-DYNA to do the elastic-plasticity large deformation process'emulational calculation of rolling process. Each major component of PSW is used to predigest the rational model for the tridimensional entity finite element model. It uses the transformation of coordinates together with the accurate position of roller axes and workpiece center line. According to the simulation data, we can analyze workpiece shape, distribution of the equivalent stress and strain, rolling force, workpiece velocity, transmission ratio of wheel train, spiral movement parameter and position of the neutral plane.The paper uses the traditional theory and programming to calculate rolling force. This method has the merit of high computing efficiency. It is easier to be used in the engineering application. The finite element simulation analysis is based on the software of ANSYS/LS-DYNA. It can establish the foundation for the advanced realization of workpiece forming law, and offer reference to design the PSW.