Simulation Of The Cage Roll-forming Process Of Thin-walled Cylindrical Member And Design Of The Bionic Anti-wear Roll

In allusion to the manufacturing need of cylindrical longitudinal member of large carrierrocket body, the manufacturing technology has difficulty in the accuracy of the shape and size.In the first half of this paper, the cage roll-forming process of thin-walled cylindrical memberwas taken as objective,. the finite element numerical simulation technology was used to predictthe deformation of thin-walled cylindrical member and verify the correctness of the model.Finally, the high-quality processing of thin-walled cylindrical member was achieved with thehelp of computer-aided design.With the development of the worldwide steel industry, Roll forming technology has beenmore and more widely used. Forming roll are the core machined part and also mainconsumable part of roll forming mill. Improving the anti-wear properties of forming roll notonly increases the production of roll bending machine but also improves the quality of steel.The latter half of this paper, under the guidance of bionics and non-smooth theory, The gridbionic surface micro-morphology was processed on the Cr20steel roll forming roll sample bylaser surface texturing to improve the anti-wear properties of the roll forming roll sample.Specific research is as follows:1. Cage roll-forming process of thin-walled cylindrical memberUsing the three-dimensional modeling software, experimental prototype model of thecomposite bending including cage roll-bending and air-bending, and experimental prototypemodel of Flexible forming which included composite bending including cage roll-bending andair-bending and precision work were established. Their transversal roller bitmaps weredesigned.2. Research on simulation of the cage roll-forming process of thin-walled cylindricalmemberSimulation models of the two experimental prototype models were established bystandard algorithm. When thin-walled cylindrical members touched, bit into and passed the forming rolls in the first pass of the two experimental prototype models, according to the Misesstress distribution of thin-walled cylindrical member, they formed normally, and the normaloperation of the entire forming process was ensured effectively. According to the deformedmesh, Mises stress, PEEQ strain, transversal stress, transversal strain, longitudinal stress andlongitudinal strain distribution of thin-walled cylindrical member in the entire forming processof the two experimental prototype models, they were incrementally formed in the longitudinaldirection and bending in the transversal direction. Quality defects didn’t appear in their areaswhere they contacted with forming rolls, and edge buckling also didn’t accrue at their edges. Ina word thin-walled cylindrical member formed uniformly in the two forming processes.3. Preparation of forming roll samples with the grid bionic surface micro-morphologyUnder the guidance of bionics and non-smooth theory, nine kinds of grid bionic surfacemicro-morphology which were different from stripe width, stripe transverse space, Stripelongitudinal space and crossing line angle had been designed. The nine kinds of grid bionicsurface micro-morphology was processed on the nine pairs of Cr20steel forming roll sampleby JG20-1laser surface texturing machine. The HRCs of nine pairs of forming roll sample withgrid bionic surface micro-morphology were Higher than the roll sample with smooth surface.4. Anti-wear experiment of forming roll samples with the grid bionic surfacemicro-morphologyAccording to the principle of the experimental optimum design, the experimental schemehad been arranged by the orthogonal experimental design. The wear tests of nine pairs offorming roll sample with grid bionic surface micro-morphology and one pairs of roll samplewith smooth surface. the wear value and the wear rate of ten different models have beenanalysed contrastively. the anti-wear properties of nine bionic grid models were better than thatof the smooth model, the range analysis was adopted for the wear value and the wear rate ofnine different models by the way of orthogonal experimental design, in the lubricationcondition, The optimizing parameters of the bionic surface morphology was Stripe width40μm,Stripe transverse space360μm, Stripe longitudinal space590μm, crossing line angle30%. Theanti-wear mechanism of bionic grid models was analysed: the change of the lubricationcondition and strengthening effect of the laser processing.