Study On Simulation Of Forming Process And Optimization Of Process Parameters In Shaped Section Ring

Profiled ring is a special ring-shaped component, such as train wheel, wheel hub, aerospace engine case, bicycle rim, piping flange plate and bearing collar, are widely used in significant fields of machinery, chemical industry, metallurgy, shipping, automobile and aviation industry. Profiled ring rolling technique is not only efficient, but also low cost. By using this ring rolling technique, high quality and good property products can be obtained. Up to now, studies about rectangular cross-section and the steps shaped cross-section ring rolling technique are relatively well-developed. However, researches on profiled ring rolling in different shapes are not well-developed. It can not satisfy the demand for the development of ring rolling production. Therefore, it is meaningful to do further study on profiled ring rolling technique.In this paper, a typical profiled ring is chosen as the study object. By rolling statics analysis based on ring rolling theory, both the rolling bite condition and forging condition are calculated. Thereby, the reasonable value range of main rolling process parameters is deduced. FORGE software is used to establish the finite element simulation model. The typical preform shape for rolling of profiled ring is designed and simulated. The cause of defects in ring rolling process is analyzed. Through gradually optimization, the optimal preform shape has been obtained. The height of vertical part in inner cone of the preform is in accordance with the height of the foundation bed. And the neck part of inner cone is in taper shape. The tilt angle in neck part is 30°. Through the finite element simulation, the change rules of rolling force and true plastic strain during rolling process of profiled ring are analyzed. And the metal flow law in the neck part and foundation bed of the ring in axial and radial directions is also studied. Ring rolling mechanism and causes of defects are revealed. This study analyzes the effect of main process parameters(core roller feeding speed, the main roller rotation angular velocity) on rolling force, true plastic strain and forming quality in rolling process. The optimal process parameters of ring rolling is obtained, that is, the main roller rotating angular velocity is 5 rad/s and the core roller feeding speed is 5 mm/s. The simulation results are used to produce the profiled ring on D52-1600 machine for verification. The optimization of preform shape and process parameters based on numerical simulation model is verified, which indicates that finite element simulation is reliable to conduct the optimization process of profiled ring rolling.According to the research results in this paper, reference information for rolling process of different profiled ring is provided. Moreover, it has engineering application value and guiding significance for the development of ring rolling application fields. Besides, energy-efficient complicated profiled ring rolling production demand can be satisfied.