The Research And Numerical Simulation Of Forging Process For Heavy Grinding Roller Shaft

As key and basic parts of large scale equipments, the level of production of the heavy forgings are proved to be an important symbol of national industry and defense force. In recent years, the rapid development of the world industrial greatly increase the requirements of large forgings gradually,and the quality requirements are also become higher and higher. With the weight and dimensions of large forgings increasing constantly,the quality requirements of the large forgings propose new issues for the forging industry .Grinding roller shaft is a key part of ATOX grinding roller and belongs to large forging. The size of grinding roller shaft is increasing with the development of large-scale equipment. It has step shaft with different cross section and 1850mm×1110mm rectangular cross-section. If general method is used,upsetting diameter of ingot should reach 2900mm, and the current 8400T hydraulic is unable to produce. If large ingot is used to forge,it will cost a huge waste of metal. Because the grinding roller shaft has a large rectangular flange,the dimensions and internal quality will be difficult to ensured in forging process. In order to improve economic efficiency and quality, the technology must be improved and innovated. The loose tooling forming process is used after analyzing.In this paper, the whole forging process and voids defects in heavy forgings were studied. Numerical simulation of voids crushing in Stretching process using DEFORM-3D for grinding roller shaft was researched. After studying the effect of voids crushing using different process parameters,the preferable process parameters is chosen.Large rectangular cross-section is formed in the loose tooling forming process. It is difficult to forge because of the corner. The forming process and die structure are studied by using finite element simulation. The appropriate process was found through improving method repeatedly. Then simulation software DEFORM-3D was used to simulate the forming process of square part using different die structure. Finally the reasonable forging process and appropriate die structure was found after analyzing and comparing according to the actual production and the eligible forgings were produced.