Numerical Simulation And Experimental Research Of Three-roll Helical Rolling

The production of precious metals bars, such as titanium, has been commercialized, standardized, massed. But the non-standard bar production, new materials research and development and other special requirements of the bar also tend to need some special methods which are flexible and can produce high performance product. In this paper, the forming theory and rolling process of three-roll helical rolling are studied with FEM numerical simulation.The two important angle-helix angle and slant angle-of three-roll helical rolling are analyzed, especially the influences of different helix angle on the loads of rollers. The surface equation of rollers and rolled piece are obtained through the coordinate transformation and the mathematical model is established.By using Deform-3D FEM software, the deformation process in three-roll helical rolling has been simulated and the stress and strain distribution, temperature field and the loads of rollers are obtained; the relationship of forming rules and process parameters is studied. The simulation results provide guidance for rolling experiment.The impact of plastic deformation and stress state of the workpiece on rolling pressure is researched and the formula of rolling force is obtained. The initial estimate of the rolling force and rolling moment are done and the simulation results and experimental results are compared which verifies the reliability of the calculation. The rolling defect and control methods are summarized by rolling experiment with different material and different specifications of the bars in a various rolling conditions. The high quality rolled piece has been rolling by the improvement of rolling process and adjustment of equipment parameters.