Forging Technology And Numerical Simulation For Heavy Supporting Roller

As the core components of sets of large equipment, large forgings play a very important role in the national economic construction, national defense equipment development and the major installations building of the modern advanced science and technology. The production capacity, product quality level and performance level of the large forgings become a symbol of a national industrial level. Supporting roller is widely used in different sizes and various specifications of rolling enterprises as the main parts of rolling production equipment. Overall forging supporting roller is the heart-type components of the rolling mill, and its working conditions have a direct relation on the surface quality and flatness of the plates. Supporting roller forging is the representation of large shaft forging, with its large and heavy characteristics. In working conditions, the roll surface usually endure tremendous stress, and high quality is required, then the manufacturing difficulty is very large. In this paper, the theory of modern forging technology is used to analyze and optimize the process of the supporting roller forging, to improve the quality.The material of the heavy supporting roller forging in this paper is 45Cr4NiMoV steel. For the 45Cr4NiMoV steel, the flow stress curves are determined through physical simulations. The development process of flow stress model is discusses, the activation energy of the steel thermoplastic deformation is calculated, and the 45Cr4NiMoV steel material model is established through the use of the material constitutive equation in the software Deform-3D. These works could provide scientific evidences for the use of the material in the field of thermal deformation and the forging process of the heavy supporting roller forging, and lay the foundation for the further study of the material.The software Deform-3D is used to simulate the process of the 45Cr4NiMoV supporting roller, based on the analysis results of the tool width ratio and material width ratio in the WHF forging stretching process, the screw-down rate per trip and the reasonable anvil variance and so on. In the simulation processes, the affects of different process parameters on the forging internal stress distribution and the internal defect elimination are analyzed. By the comparison of the simulation results, the forging process of the heavy supporting roller forging is optimized.In this paper, the research findings of 45Cr4NiMoV heavy supporting roller materials and its forging technology, lay a favorable foundation for the further work of the large forgings internal cracks simulation.