Forming Laws Research And Technology&Equipment Design For Rolling Processing Of Complex Deep-groove Ring

Complex deep-groove ring belongs to profile ring which has the geometrical characteristicof asymmetric deep-groove on the outer surface. This kind of ring part is widely used in the fieldof automobile, engineering machinery, petrochemical industry, etc. Due to the special geometriccharacteristics, it’s difficult to obtain the complete section profile directly by traditional forgingprocess or special ring rolling technology. Three-roll cross rolling (TRCR) is a new advancedplastic process of forming ring parts with deep groove directly by three-roll rotary rolling, whichmakes the blank produce successive partial plastic deformation. Combined ring rolling (CRR) isanother new process of forming ring parts with deep groove based on TRCR and ring rolling.Compared to deep-groove ring with symmetrical geometric features, the metal flow behavior inrolling process of complex deep-groove ring is more complex. To manufacture complexdeep-groove ring with low energy consumption, high production efficiency and superior productquality, it’s necessary to research on forming technology and equipment of TRCR and CRR.In this paper, the design method for blank, rolls and forming parameters of TRCR and CRRto produce complex deep-groove ring was proposed through theoretical analysis. Because ofspecial geometric characteristics, the requirement for blank shape and size was high. Base onestablishing a reliable3D coupled thermo-mechanical FE model, the three designed blanks werestudied. We found the simulation result was similar to the theoretical analysis, but the formingeffect needs to be improved. So we put forward the blank optimization design method to formthe complex deep-groove ring precisely. To understand the process of TRCR and CRR toproduce complex deep-groove ring deeply, the FE method was used to analyze the two rollingprocesses with stepped blank. And the changing rules of geometric size, equivalent strain,temperature field and force parameters in rolling process were revealed. Further, the effects ofrotate speed, feed rate, the initial rolling temperature and the friction coefficient on thedeformation quality of rolled ring were analyzed. The results provide some scientific guidancefor actual technology development of complex deep-groove ring.To match technology development, the equipment for TRCR and CRR of complexdeep-groove ring was designed in this paper. According to the technology requirements of TRCRand CRR, the combined rolling equipment structure which was appropriate for these two processes was proposed base on traditional vertical ring rolling machine. Through theoreticalcalculation, rolling force parameters of equipment and structure and size of key parts wereconfirmed. According to the movement requirements, the hydraulic system was designed. TheCAD model of combined rolling equipment was established in PRO/E software. The keycomponents were analyzed by using the FE software ABAQUS. Based on ADAMS software, themotion of virtual equipment and hydraulic system were simulated and analyzed. Finally, thefeasibility of the equipment design was confirmed, and the experimental combined rollingmachine was manufactured.